LED Lighting System with Braided Insulation

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Solution Overview

Problem

Existing lighting systems face challenges in durability and management of wires and light fixtures, particularly when exposed to harsh conditions, as they tend to become entangled and damaged, and existing solutions fail to protect light fixtures without impacting light output.

Innovation Solution

A lighting system comprising a plurality of conductive wires with a braided layer providing insulation, wear resistance, and wire containment, along with a USB plug, where the wires are arranged side-by-side and encapsulated in a transparent insulated layer, which includes polymer material and is UV light resistant, to manage and protect the wiring and light fixtures effectively.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If wires are made flexible and extendable for lighting applications, then ease of operation and adaptability improve, but wire durability and resistance to breaking deteriorate due to repeated bending

Engineering Contradiction:

Improvewire flexibilityVSAvoidwire durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The wire is segmented into multiple individual strands rather than a single solid conductor. Each strand can bend independently, allowing the wire to flex repeatedly without breaking while maintaining electrical conductivity. This segmentation resolves the contradiction by enabling flexibility without compromising durability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The wire combines multiple material properties: conductive metal strands for electrical function, plastic coating for insulation and protection, and braided fabric layers for mechanical strength and flexibility. This composite structure allows the wire to be both flexible and durable simultaneously.

Inventive Principle:

Principle #40Composite materials

2Power

If multiple wires are extended in parallel for power transmission, then power delivery capability improves, but wire management and entanglement resistance deteriorate

Engineering Contradiction:

Improvepower transmission capabilityVSAvoidwire management

Core Design Contradiction:

PowerVSEase of operation

Solution Approach 1:

Multiple individual wires are merged into a single bundled cable assembly with integrated power and data conductors. The braided fabric and plastic coating bind the wires together, preventing entanglement while maintaining the ability to transmit multiple signals and power simultaneously.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The cable assembly serves multiple functions: power transmission, data communication, and physical protection. The integrated design combines what would otherwise be separate wire management systems into a single universal solution that handles both power delivery and wire organization.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Device complexity

If light fixtures are mounted directly to wires for compact design, then device complexity reduces, but protection from environmental damage and wire durability deteriorate

Engineering Contradiction:

Improvemounting structure simplicityVSAvoidprotection from damage

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

A flexible plastic coating and braided fabric sheath are applied over the wire assembly, creating a protective shell that shields mounted light fixtures from environmental damage. This thin-film protection maintains the compact design while adding durability against moisture, physical damage, and wear.

Inventive Principle:

Principle #30Flexible shells and thin films

4Reliability

If protective coatings are applied to light fixtures for harsh environment protection, then reliability and durability improve, but light output and illumination intensity deteriorate

Engineering Contradiction:

Improveprotection from environmental conditionsVSAvoidlight output

Core Design Contradiction:

ReliabilityVSIllumination intensity

Solution Approach 1:

A thin, transparent or translucent plastic coating is applied to the light fixture. This thin film provides environmental protection while allowing light to pass through with minimal attenuation, maintaining illumination intensity while protecting against harsh conditions.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The protective coating uses materials with specific optical properties that balance protection and light transmission. The composite structure allows environmental resistance while preserving light output through careful material selection.

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS11199299B2LED lighting system and methods

Publication Date: 2021.12.14 REVEL GEAR LLC

AI summary

An LED lighting system includes first, second and third conductive wires, a plurality of light emitting diodes (LEDs), a transparent insulated layer, and a universal serial bus (USB) plug. The first conductive wire is configured to carry a positive charge. The second conductive wire is configured to carry a negative charge. The third conductive wire is configured to carry a ground charge. The first, second and third conductive wires are arranged side-by-side. The plurality of LEDs are mounted to each of the first, second and third conductive wires. The transparent insulated layer extends around and encapsulates the first, second and third conductive wires and the plurality of LEDs. The USB plug is electrically connected to the first, second and third conductive wires.