In-Plane Bent Printed Circuit Boards for Lighting Fixtures

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Solution Overview

Problem

Metal-core printed circuit boards (MCPCBs) are often wasted due to their fixed sizes not matching lighting fixture dimensions, requiring trimming and material loss during customization.

Innovation Solution

A printed circuit board designed as a long, narrow strip of repeating units connected by bridges, allowing in-plane deformation into desired shapes like a ring, and self-retaining configurations to avoid material waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If MCPCBs are used in fixed predetermined sizes, then manufacturing is simplified and production efficiency is improved, but adaptability to different lighting fixture dimensions is worsened

Engineering Contradiction:

Improveproduction efficiencyVSAvoidadaptability to fixture dimensions

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The MCPCB is divided into multiple repeating units connected by bridges, allowing the board to be segmented and reconfigured into different shapes while maintaining manufacturing efficiency through standardized modular components

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The board transitions from a static fixed-size configuration to a dynamic flexible structure that can be bent and shaped into different configurations to match various lighting fixture dimensions

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If MCPCBs are trimmed to match lighting fixture dimensions, then adaptability is improved, but material waste increases

Engineering Contradiction:

Improveadaptability to fixture dimensionsVSAvoidboard material waste

Core Design Contradiction:

Adaptability or versatilityVSLoss of substance

Solution Approach 1:

The board is pre-configured with repeating units and bridges that enable future shaping operations, allowing the board to be adapted to different fixture dimensions without trimming and material waste

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The board's shape parameter is changed through bending rather than material removal, transforming the board into different configurations while preserving all original material

Inventive Principle:

Principle #35Parameter changes

3Adaptability or versatility

If MCPCBs are bent into desired shapes, then adaptability to fixture dimensions is improved, but structural stability is worsened

Engineering Contradiction:

Improveadaptability to fixture dimensionsVSAvoidstructural stability

Core Design Contradiction:

Adaptability or versatilityVSStability of the object's composition

Solution Approach 1:

The board is segmented into repeating units with bridges that create natural bending zones, allowing controlled deformation while maintaining structural integrity through the modular design

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The MCPCB composite structure (metal core, dielectric layer, copper traces) is designed to accommodate bending stresses while maintaining electrical and mechanical stability in the deformed configuration

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS8840271B2In-plane bent printed circuit boards

Publication Date: 2014.09.23 ABL IP HLDG LLC

AI summary

In certain embodiments there is provided a blank for a printed circuit board and methods pertaining to same. In some embodiments, the blank is provided in a generally straight configuration and is capable of being deformed in-plane into a bent configuration, such as, but not limited to, a generally ring-shaped configuration, a generally square shape, or a generally S-shape. In some embodiments, the PCB is used with a lighting fixture and is populated with light emitting diodes.