Folded Flexible Light Sheets for Customizable LED Illumination

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Solution Overview

Problem

Conventional lighting systems face challenges in achieving uniform and customizable illumination due to the rigidity and limited flexibility of existing illumination sources, such as fluorescent tubes and incandescent lamps, which restricts their application in various lighting designs and increases costs and complexity.

Innovation Solution

The use of flexible light sheets that can be folded to customize length and shape, incorporating light-emitting elements and reflective or conductive portions to enhance light distribution and power management, allowing for adjustable illumination patterns without the need for multiple circuit boards or complex interconnects.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional illumination sources (fluorescent tubes, incandescent lamps) are used, then fixed lengths and shapes are achieved, but customization for specific geometries is precluded

Engineering Contradiction:

Improvecustomization for specific geometriesVSAvoidcost-effective manufacture

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The illumination source is divided into multiple discrete LED elements mounted on a flexible substrate, allowing the linear luminaire to be cut and configured to different lengths while maintaining uniform illumination characteristics

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A flexible printed circuit board substrate is used to mount the LED elements, enabling the rigid LEDs to be arranged in customizable geometries and lengths while maintaining structural integrity and electrical connectivity

Inventive Principle:

Principle #30Flexible shells and thin films

2Illumination intensity

If multiple LEDs are used to achieve high spatial uniformity, then illumination uniformity is improved, but system cost increases due to large numbers of LEDs required

Engineering Contradiction:

Improvespatial uniformityVSAvoidsystem cost

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

A single optimized circuit board design with specific LED spacing and arrangement is replicated multiple times to create luminaires of different lengths, achieving consistent uniformity performance without redesigning the entire system

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The flexible circuit board design serves multiple functions: it provides mechanical support for LEDs, electrical connectivity through traces, heat dissipation pathways, and enables customization through cutting and folding operations

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If custom circuit boards are designed for different luminaire geometries, then specific shapes and lengths are achieved, but manufacturing time and cost increase

Engineering Contradiction:

Improvedifferent geometriesVSAvoidmanufacturing efficiency

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The luminaire is designed as a modular system where a standardized circuit board segment can be cut to different lengths and combined with identical end fixtures, eliminating the need to design custom circuit boards for each length

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The only parameter that changes between different luminaire models is the length, achieved by cutting the flexible circuit board to different lengths while maintaining all other design parameters (LED spacing, trace width, component placement) constant

Inventive Principle:

Principle #35Parameter changes

4Stability of the object's composition

If rigid illumination sources are used, then structural stability is maintained, but curved or arbitrarily shaped configurations are precluded

Engineering Contradiction:

Improvestructural stabilityVSAvoidcurved or arbitrary shapes

Core Design Contradiction:

Stability of the object's compositionVSShape

Solution Approach 1:

The circuit board uses a flexible substrate that can be bent and folded to create curved or arbitrary shapes while maintaining electrical connectivity and mechanical stability through the flexible PCB structure

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The luminaire transitions from a rigid structure to a dynamically configurable structure that can be installed in different geometries (linear, curved, angled) while maintaining structural integrity through the flexible circuit board design

Inventive Principle:

Principle #15Dynamics

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enables cost-effective, reliable, and efficient customization of lighting systems with improved uniformity and ease of installation, accommodating diverse lighting applications and geometries while maintaining high luminous efficacy.

Implementation Method 1

a plurality of light-emitting elements disposed over the first surface of the substrate

Methodology Applied

Scientific EffectLight-emitting diode: Light Emitting Diode

Implementation Method 2

A first portion of the light sheet is folded beneath a second portion of the light sheet along a line not parallel to the first direction

Methodology Applied

Scientific EffectFolding: Folding

Data Source

PatentUS10393330B2LED lighting system incorporating folded light sheets

Publication Date: 2019.08.27 COOLEDGE LIGHTING

AI summary

In accordance with certain embodiments, flexible light sheets are folded to define first and second portions of the light sheet divided by the fold, and the first and second portions of the light sheet may both feature light-emitting elements thereon.