LED Substrate with Separable Functional Sections for Simultaneous Processing
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Solution Overview
Problem
The existing surface mounted technology for manufacturing LED light strips results in scrap material and increased processing time due to the need for individual assembly and replacement of entire sets when only a part is damaged, leading to inefficiency and waste.
Innovation Solution
A substrate with parallel-arranged functional sections and connecting sections that allows separation into two identical daughter substrates, enabling simultaneous processing and eliminating scrap material, with the option to reconnect for convenience and assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the circuit board is cut into separate LED light strips after mounting, then individual LED strips can be manufactured, but scrap material is produced and usable area is reduced
Solution Approach 1:
The substrate is designed with separable functional sections that can be divided into two identical daughter substrates. Each daughter substrate contains complete functional units (LEDs, circuits, connectors), allowing the board to be segmented into usable portions without producing scrap material. The segmentation is achieved through symmetric arrangement of functional sections around a central dividing line.
2Ease of operation
If LED light strips are assembled and processed one by one, then individual processing can be performed, but processing time increases
Solution Approach 1:
Two identical daughter substrates are kept connected on a single substrate during the mounting and processing stages, allowing simultaneous processing of both halves. The symmetric design with central dividing line enables SMT machines to mount LEDs and process circuits on both daughter substrates at the same time, effectively doubling productivity while maintaining individual processing capability.
3Area of stationary object
If the substrate is designed with separable functional sections, then usable area doubles and no scrap is produced, but device complexity increases
Solution Approach 1:
The substrate employs symmetric design rather than asymmetric complexity. By arranging functional sections symmetrically around a central dividing line, the design achieves simplicity through symmetry. Each half is a mirror image of the other, reducing design complexity while maximizing usable area. The symmetric structure allows straightforward segmentation into two identical daughter substrates without complex routing or asymmetric component placement.
Data Source
AI summary
A substrate of the present invention is provided with a plurality of parallel-arranged functional sections. First and second connecting sections are provided on both ends of the functional sections. Every two adjacent functional sections are separable from one another and are respectively connected with different connecting sections so that the substrate can be separated into two daughter substrates having identical areas. The two daughter substrates of the substrate can be processed simultaneously before separated from each other, thus saving the processing time. When used by a user, one daughter substrate can be used independently as a light source or the two daughter substrates can be used opposite to each other so that the functional sections of the two daughter substrates are staggered.