Low Profile Extrusion Housing for LED Diffusion and Durability
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Solution Overview
Problem
Existing housings for light-emitting devices, such as LEDs, are not durable enough for outdoor use, cannot be easily customized to fit various structures, and often compromise light diffusion and environmental protection.
Innovation Solution
A low-profile extrusion housing made from clear materials with diffusive properties, featuring a hollow center for easy mounting of light-emitting devices and customizable lengths, along with end caps that provide environmental protection and accommodate thermal expansion, while allowing for efficient light diffusion and easy installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If flexible tape with adhesive is used to house LEDs, then ease of installation is improved, but durability for outdoor use deteriorates
Solution Approach 1:
The patent uses a flexible corrugated housing structure made from durable materials like metal or rigid plastic that maintains flexibility for easy installation while providing environmental protection for outdoor use. The corrugated design allows the housing to be bent and conform to surfaces while maintaining structural integrity and protection against moisture and damage.
Solution Approach 2:
The patent employs composite construction by combining the flexible corrugated housing with rigid LED mounting plates and protective end caps. This composite approach integrates the ease of installation from flexible materials with the durability of rigid materials, creating a housing system that performs well in outdoor environments.
2Shape
If translucent tube is used to house LEDs, then light diffusion is improved, but light brightness deteriorates due to attenuation
Solution Approach 1:
The patent applies different optical properties to different parts of the housing. The corrugated sections provide light diffusion and directional control, while the end caps and mounting plates provide structural support and electrical connection. This localized functional differentiation allows optimal light delivery without excessive attenuation.
Solution Approach 2:
The corrugated housing features curved and angled surfaces that redirect and distribute light in multiple directions. The wave-like pattern of the corrugations creates multiple light pathways that enhance diffusion while minimizing direct attenuation, as light travels shorter distances through the housing material.
3Ease of manufacture
If fixed length housing is used, then manufacturing simplicity is improved, but adaptability to different structures deteriorates
Solution Approach 1:
The patent designs the housing as a modular system with standardized corrugated sections that can be connected end-to-end to create custom lengths. Each segment is identical and can be manufactured independently, then assembled to match the specific requirements of different structural surfaces and applications.
Solution Approach 2:
The flexible corrugated housing can be dynamically adjusted and bent to conform to various surface geometries. The same standardized housing can be installed on curved surfaces, flat surfaces, or angled surfaces by simply adjusting the curvature of the corrugated sections, providing adaptability without requiring custom-manufactured components.
4Reliability
If sealed housing is used to protect from environment, then reliability is improved, but thermal expansion accommodation deteriorates
Solution Approach 1:
The flexible corrugated housing structure inherently accommodates thermal expansion through its wave-like geometry. The corrugated sections can expand and contract in response to temperature changes while maintaining the sealed protective environment. The flexibility of the housing material allows it to absorb thermal stresses without compromising the seal integrity.
Solution Approach 2:
The housing design incorporates expansion joints and flexible sealing mechanisms that allow dimensional changes due to thermal expansion. The corrugated structure's varying cross-section creates natural expansion chambers that accommodate volume changes while maintaining environmental protection. Sealing elements are designed to flex with temperature-induced dimensional changes.
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
The solution enhances the durability and customization of light-emitting device housings, improves light diffusion, and provides effective environmental protection, reducing manufacturing complexity and costs while maintaining the functionality of the devices.
Implementation Method 1
made from clear materials with diffusive properties
Implementation Method 2
end caps that provide environmental protection and accommodate thermal expansion
Data Source
Figure 1~3
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Figure 6~9
AI summary
The present invention provides various embodiments for apparatuses and methods of manufacturing low profile housings for electronic and/or optoelectronic devices. Some embodiments provide low profile housings with a hollow casing comprising a first surface, second surface, and at least one lateral side surface. The housing is substantially light- diffusive. At least one cap (78) is provided for sealing an end of the casing (12), with the at least one cap being sized to account for variations in the casing. At least one light emitting device (188), such as an LED, may be mounted within the casing. A mounting means may be included for mounting the housing. In another embodiment, a low profile housing with a first casing and second casing surrounding a majority of the first casing may be provided. At least one light emitting device, such as a double-sided printed circuit board with a plurality of LEDs, may be provided in the first casing. One or more end caps may be provided for sealing both the first and second casings. Two different wavelengths of light may be emitted from either side of the housing.