Integrally Formed LED Light Wire with Scattering Encapsulant
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Solution Overview
Problem
Conventional LED light wires are inadequate for outdoor use due to insufficient protection against mechanical damage and environmental hazards, and their manufacturing processes are labor-intensive and costly, limiting their flexibility and functionality.
Innovation Solution
An integrally formed single piece LED light wire with a support substrate, conductive bus elements, and encapsulant that includes light scattering particles, allowing for flexible and efficient manufacturing with enhanced protection and functionality, including 360° illumination and programmable light patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional protective tube is used to house internal circuitry, then the light wire is protected from environmental hazards, but the protection against mechanical damage is insufficient and the manufacturing process becomes labor-intensive
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 housing the circuitry, reducing labor intensity while maintaining environmental protection.
Solution Approach 2:
The protective tube serves multiple functions simultaneously: it provides environmental protection, acts as the structural housing, and integrates the circuit board mounting structure. This multi-functionality reduces the number of separate components and assembly steps required in manufacturing.
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 decreases and the process becomes labor-intensive
Solution Approach 1:
The patent replaces rigid sheet or hard lamination encapsulation with a flexible encapsulant material that can conform to the light wire structure while providing protection. This flexible encapsulation maintains the wire's bendability and flexibility while still protecting the internal circuitry from environmental damage.
3Reliability
If complex LED circuit assembly process and soft lamination process are used for LED light strips, then increased protection is achieved, but the manufacturing cost and time increase
Solution Approach 1:
The circuit board is pre-formed with mounting structures and circuit traces before being integrated into the protective tube. This preliminary preparation allows for automated assembly processes and reduces the complexity of the final assembly step, improving manufacturing efficiency while maintaining protection levels.
4Shape
If conventional light wire structure with air gap is used, then the protective tube provides housing, but the protection against mechanical damage due to excessive loads is insufficient
Solution Approach 1:
The patent eliminates the air gap between the protective tube and internal circuitry by integrating the circuit board directly into the tube structure. This integration provides structural support and cushioning to the internal components, protecting them from mechanical damage due to excessive loads while maintaining the protective housing function.
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 provides a flexible, protected, and cost-effective LED light wire with uniform lighting and additional features like programmable light patterns, suitable for various applications, including outdoor use.
Implementation Method 1
encapsulant that includes light scattering particles, allowing for flexible and efficient manufacturing with enhanced protection and functionality, including 360° illumination
Data Source
AI summary
An 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 includes a support substrate, a conductive base formed on the support substrate, the conductive bus comprising a plurality of conductive bus elements, at least one conductive segment arranged between the plurality of conductive bus elements, the at least one conductive segment comprising at least one LED. The integrally formed single piece LED light wire may include built-in sensors/detectors and/or a plurality of LED modules with individually controlled LEDs via microprocessors. The integrally formed single piece LED light wire may also include an interlocking alignment system which permits the coupling of at least two LED light wires. Further, a plurality of the integrally formed single piece LED light wires may create a lighting panel.