LED Lighting Strip Wire Bends for Thermal Expansion
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Solution Overview
Problem
Existing LED lighting strips for vehicles face reliability issues due to thermal expansion mismatches between the enclosing member and central wire, particularly under varying ambient temperatures and LED operation, which can lead to electrical breakthroughs and reduced durability.
Innovation Solution
Incorporating bends in both the outer and central wires of the LED lighting strip, with controlled orientations and distances to maintain insulation and flexibility, and using materials with compatible thermal expansion coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the enclosing member and central wire are made with different thermal expansion coefficients to accommodate thermal expansion mismatches, then thermal stress management is improved, but manufacturing precision and structural stability deteriorate due to the need for bends and controlled orientations
Solution Approach 1:
The patent introduces bends in the central wire and outer wires instead of maintaining straight configurations. These curved sections allow the wire structure to accommodate thermal expansion mismatches between the enclosing member and central wire by flexing during temperature changes, thereby reducing thermal stress while maintaining structural integrity
Solution Approach 2:
The patent modifies the physical parameters of the wire structure by introducing bends with specific orientations and distances between them. This changes the mechanical properties of the wire assembly, allowing it to flex and adapt to thermal expansion differences while maintaining electrical connectivity and structural stability
2Ease of operation
If bends are added to the outer and central wires to enhance bendability and flexibility, then ease of operation is improved, but device complexity increases due to additional structural elements and manufacturing steps
Solution Approach 1:
The patent divides the wire structure into multiple segments by introducing bends at specific locations between adjacent LEDs. This segmentation allows different portions of the wire to move independently, enhancing overall flexibility and bendability while maintaining electrical connectivity through the bent sections
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
Enhances the bendability, twistability, and mechanical stability of the LED lighting strip, reducing the risk of electrical breakthroughs and improving thermal stress management.
Implementation Method 1
reliability issues due to thermal expansion mismatches between the enclosing member and central wire
Data Source
AI summary
An LED lighting strip, method of manufacturing an LED lighting strip and an automotive lighting system are described. The LED lighting strip (100) includes at least two outer wires (12, 14), at least one central wire (15) between the two outer wires, LEDs (22) arranged along the LED lighting strip and electrically coupled at least to the at least two outer wires (12, 14), and an enclosing member (52) enclosing the at least two outer wires, the at one central wire and the LEDs. The at least two outer wires (12, 14) and the least one central wire (15) have a bend (51) in sections between at least some adjacent LEDs (22).