Foldable Interleaved LED Carrier for Directional Light Mixing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional LED light strips emit light in a fixed direction, limiting flexibility and directionality, and lack functionality for light mixing and collimation.
Innovation Solution
A lighting device comprising foldable elongated carriers with interleaved sections that allow for adjustable light emission directionality, incorporating flexible printed circuit boards and light-emitting elements, enabling light mixing and collimation through selective positioning of LEDs within cavities formed by the interleaved structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional LED light strips are used with flat flexible PCBs and LEDs arranged on one side, then the structure is simple and easy to manufacture, but the light emission direction is fixed and lacks flexibility
Solution Approach 1:
The lighting device is divided into multiple sections along its length, with each section capable of being folded independently. The flexible PCB is segmented into multiple sections that can be folded at defined locations, allowing different sections to be oriented at different angles. This segmentation enables the light emission direction to be adjusted for each section while maintaining overall structural simplicity.
Solution Approach 2:
The carrier structure is designed to be dynamically foldable rather than rigidly fixed. The flexible PCB allows the sections to be folded to different angles and positions, enabling dynamic adjustment of light emission directions. This dynamic capability provides versatility in light directionality while the underlying flexible PCB structure maintains manufacturing simplicity.
2Adaptability or versatility
If LEDs are arranged on a flat flexible PCB, then the manufacturing process is simple, but light mixing and collimation functionality cannot be achieved
Solution Approach 1:
The patent transitions from a two-dimensional flat PCB arrangement to a three-dimensional folded structure. By folding the PCB sections at different angles and positions, the LEDs are positioned in multiple spatial dimensions, enabling light mixing and collimation functionality. The folded carrier structure creates depth and angular variation that a flat PCB cannot achieve, while the flexible PCB material itself remains simple to manufacture.
3Adaptability or versatility
If the flexible PCB is folded into an interleaved structure, then light emission directionality and light mixing are improved, but the manufacturing complexity increases
Solution Approach 1:
The folding process is simplified by segmenting the PCB into predefined sections with designated fold lines. Each section can be folded independently to a specific angle, making the manufacturing process more manageable. The segmentation allows for standardized folding procedures and facilitates quality control during assembly.
Solution Approach 2:
The PCB is designed with pre-defined fold lines and section divisions that guide the folding process. This preliminary structuring of the flexible PCB makes it easier to achieve the desired interleaved configuration during manufacturing, reducing the complexity of the folding operation compared to creating folds without pre-defined guides.
4Temperature
If multiple sections are folded over each other to form an interleaved structure, then thermal management is enhanced, but the device complexity increases
Solution Approach 1:
The interleaved structure is achieved through dynamic folding of flexible PCB sections rather than complex rigid mechanical assemblies. The flexible nature of the PCB allows sections to be folded and positioned to create thermal management pathways without requiring additional complex components. The same flexible structure that enables light directionality adjustment also provides thermal management benefits.
Data Source
AI summary
A lighting device (1) is disclosed, comprising at least a first elongated carrier (2) and a second elongated carrier (3), each of the first elongated carrier (2) and the second elongated carrier being foldable (3). At least the first elongated carrier (2) and the second elongated carrier (3) have been folded over each other such that a plurality of sections (16) of the first elongated carrier (2) are interleaved with respect to a plurality of sections (17) of the second elongated carrier (3) so as to form an interleaved structure (10). The interleaved structure (1) may have been arranged such that a plurality of cavities (9) in the interleaved structure (10) are formed, each cavity (9) at least being constituted by a surface (12) of one of the sections (16) of the first elongated carrier (2) and a surface (13) of one of the sections (17) of the second elongated carrier (3), wherein the surfaces (12, 13) of the sections (16, 17) of the first elongated carrier (2) and the second elongated carrier (3), respectively, at least in part face each other.