Low-Profile LED Extrusion Housing for Outdoor Light Diffusion
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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 suffer from light attenuation and inadequate environmental protection.
Innovation Solution
A low-profile extrusion housing with a light-diffusive casing and end caps that can be customized in length, made from materials like acrylic with added diffusants, and designed to securely mount LEDs or printed circuit boards, providing environmental protection and efficient light diffusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If flexible adhesive tape with LEDs is used for lighting strips, then the strip can be formed into various characters and provides uniform illumination, but the adhesive tape deteriorates when exposed to outdoor elements and is not durable enough for outdoor use
Solution Approach 1:
The patent uses a flexible printed circuit board (PCB) instead of adhesive tape to mount LEDs. The flexible PCB maintains the ability to be formed into various shapes and configurations while providing superior durability and resistance to environmental conditions compared to adhesive tape. This resolves the contradiction by replacing the flexible but deteriorating adhesive tape with a flexible yet durable rigid substrate.
2Adaptability or versatility
If flexible adhesive tape with LEDs is used, then the strip can be cut to different lengths for custom applications, but the adhesive and tape structure cannot withstand outdoor environmental conditions
Solution Approach 1:
The flexible PCB serves as a cuttable yet durable substrate that can be customized to different lengths while maintaining structural integrity and environmental resistance. Unlike adhesive tape, the flexible PCB can be cut and reconnected using standard electronics techniques, providing both adaptability and reliability for outdoor installations.
3Adaptability or versatility
If a translucent tube structure is used for perimeter lighting, then multiple LEDs can be arranged within the tube, but the tube significantly attenuates the light emitted by LEDs, reducing brightness
Solution Approach 1:
The patent employs lenses with specific optical properties and reflective surfaces to enhance light extraction and direction from LEDs. By optimizing the optical characteristics of the housing and lens materials, the system maximizes light transmission while maintaining the protective enclosure, thereby resolving the contradiction between structural arrangement and light brightness.
4Object-affected harmful factors
If a translucent tube is used for LED housing, then the structure can protect LEDs, but the tube significantly attenuates light and reduces the brightness of the emitted light
Solution Approach 1:
The patent uses optimized lens materials and reflective coatings to enhance light transmission while maintaining protective enclosure. The optical design ensures that the housing protects LEDs from environmental damage while minimizing light attenuation, thereby preserving brightness.
Solution Approach 2:
The housing employs composite material construction combining protective enclosure materials with optically transparent or translucent sections. This allows the structure to provide environmental protection while maintaining high light transmission efficiency, resolving the contradiction between protection and brightness.
5Object-affected harmful factors
If standard housing structures are used for LED mounting, then the housing can protect electronic elements, but the housing does not provide effective light diffusion and creates visible seams that affect aesthetics
Solution Approach 1:
The patent incorporates diffusing lenses and opaque or translucent housing materials that evenly distribute light output. The lens design and material selection eliminate visible seams and create uniform light diffusion, resolving the contradiction between protective enclosure and aesthetic light distribution.
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 extends the life of the devices while reducing manufacturing complexity and costs.
Implementation Method 1
A low-profile extrusion with a hollow, elongated casing that is substantially light-diffusive
Data Source
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 is provided for sealing an end of the casing, with the at least one cap being sized to account for variations in the casing. At least one light emitting device, 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.