Integrally Formed Single Piece LED Light Wire

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Solution Overview

Problem

Conventional LED light wires are prone to mechanical damage and environmental hazards due to inadequate protection, and their manufacturing processes are labor-intensive and costly, limiting their flexibility and efficiency.

Innovation Solution

An integrally formed single piece LED light wire with a conductive base and encapsulant that includes light scattering particles, providing comprehensive protection and flexible manufacturing, allowing for uniform lighting and reduced component complexity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional protective tube is used to house internal circuitry, then the light wire is protected from environmental hazards, but the protective tube provides little protection against mechanical damage and the manufacturing process is labor-intensive

Engineering Contradiction:

Improveprotection from environmental hazardsVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the protective tube and internal circuitry into a single integrated unit where the circuit board is formed directly within the protective tube structure. This merging eliminates the need for separate assembly steps of placing circuitry into the tube, reducing manufacturing complexity while maintaining environmental protection.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The protective tube serves multiple functions simultaneously: it provides environmental protection, acts as a structural support, and integrates the circuit board mounting function. This multi-functionality reduces the number of separate components needed and simplifies the overall manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If conventional sheet or hard lamination process is used to encapsulate light wire, then the internal circuitry is protected, but the flexibility of the light wire is decreased

Engineering Contradiction:

Improveprotection of internal circuitryVSAvoidflexibility of light wire

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent uses a flexible encapsulant material that forms a thin protective layer around the internal circuitry within the protective tube. This flexible encapsulation maintains the light wire's bendability and flexibility while still providing protection against environmental hazards and mechanical damage.

Inventive Principle:

Principle #30Flexible shells and thin films

3Reliability

If pre-assembly using soldering or crimp methods is used to connect illuminant devices, then the connections are secure, but the manufacturing process is labor-intensive and flexibility is reduced

Engineering Contradiction:

Improveconnection securityVSAvoidmanufacturing efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent replaces traditional mechanical connection methods (soldering, crimping) with a direct mounting system where illuminant devices are secured through the integrated circuit board structure within the protective tube. This substitution eliminates complex mechanical assembly steps while maintaining secure connections, significantly improving manufacturing efficiency.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of operation

If conventional light wire structure is used, then the components are easily replaceable, but the protection against mechanical damage and environmental hazards is insufficient

Engineering Contradiction:

Improvecomponent replaceabilityVSAvoidmechanical damage and environmental exposure

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The patent segments the light wire into modular sections where the protective tube, circuit board, and illuminant devices are integrated as replaceable units. This segmentation allows entire protected sections to be replaced as single modules, maintaining ease of replacement while ensuring each component is adequately protected within its integrated housing.

Inventive Principle:

Principle #1Segmentation

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 protection against mechanical and environmental damage, reduces manufacturing complexity and costs, and achieves flexible and uniform lighting effects, making it suitable for various applications.

Implementation Method 1

Methodology Applied

Scientific EffectLight scattering: Scattering

Data Source

PatentUS8789971B2Integrally formed single piece light emitting diode light wire

Publication Date: 2014.07.29 HUIZHOU LIGHT ENGINE LTD

AI summary

A flexible, integrally formed single piece light emitting diode (LED) light wire that provides a smooth, uniform lighting effect from all directions of the LED light wire. The integrally formed single piece LED light wire contains a conductive base comprising first and second bus elements formed from a conductive material. The bus elements distribute power from a power source to LEDs that are mounted on the first and second bus elements so that it draws power from and adds mechanical stability to the first and second bus elements. The flexible, integrally formed single piece LED light wire is assembled so that the first and second bus elements are connected to each other prior to the LED being mounted and such integrally formed single piece LED light wire is formed without a substrate.