Flexible Light Strip Bracket with Rib Positioning for Light Coupling

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Solution Overview

Problem

Conventional methods of assembling flexible light emitting strips with optical parts result in gaps and inaccurate positioning, affecting light coupling efficiency and optical processing quality.

Innovation Solution

A bracket with projections or ribs is used to establish line-to-face contact with the flexible light emitting strip, allowing for precise positioning and improved light coupling by adjusting the shape and distribution of these features through injection molding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If face-to-face contact assembly method is used between flexible light emitting strip and bracket, then assembly is simple, but gaps are formed and positioning accuracy deteriorates

Engineering Contradiction:

Improveassembly simplicityVSAvoidpositioning accuracy

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

The bracket's contact surface is segmented into multiple projections (ribs) instead of a continuous flat surface. These discrete projections make line-to-face or dot-to-face contact with the flexible light emitting strip, eliminating gaps while maintaining assembly simplicity through the modular projection structure.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The contact interface transitions from face-to-face (2D surface contact) to line-to-face or dot-to-face (1D line or 0D point contact). This dimensional change allows the projections to precisely locate the flexible light emitting strip at specific points or lines, dramatically improving positioning accuracy without complicating the assembly process.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

2Strength

If adhesive tape or glue is applied to improve positioning, then fixing strength is improved, but gaps between flexible light emitting strip and optical part are difficult to eliminate completely

Engineering Contradiction:

Improvefixing strengthVSAvoidpositioning accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The adhesive bonding system is replaced with a mechanical positioning system using projections (ribs) on the bracket. These projections physically contact and locate the flexible light emitting strip through line-to-face or dot-to-face contact, providing both fixing strength and precise positioning without the gap issues associated with adhesive methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Manufacturing precision

If projections are added to bracket for accurate positioning, then positioning accuracy is improved, but device complexity increases

Engineering Contradiction:

Improvepositioning accuracyVSAvoidbracket structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The projections (ribs) on the bracket are designed with adjustable parameters including height, width, spacing, and distribution patterns. By optimizing these geometric parameters during the injection molding process, high positioning accuracy is achieved while keeping the bracket structure relatively simple and manufacturable.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The projections serve multiple functions simultaneously: they provide mechanical support for the flexible light emitting strip, enable precise positioning through line-to-face or dot-to-face contact, and can be integrated into the injection molding process without requiring additional manufacturing steps. This multi-functionality reduces overall device complexity despite adding positioning features.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentEP3904753B1Bracket, light module including the same and method for manufacturing the same

Publication Date: 2025.11.12 LUMILEDS LLC

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Figure 3A~3B
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AI summary

The disclosure provides a bracket (100) for assembling a flexible light emitting strip (210) in a light module (200), the light module (200) including the bracket (100) and a method (600) for manufacturing the bracket (100). The bracket (100) includes: a base plate (110), including a first side edge (110a) and a second side edge (110b) opposite to each other; a first side plate (120a), located along the first side edge (110a), extending from the base plate (1110) and including at least one first engagement member (121); and a second side plate (120b), located along the second side edge (110b), extending from the base plate (110), opposite to the first side plate (120a) and including at least one another first engagement member (121); wherein the base plate (110), the first side plate (120a) and the second side plate (120b) form a groove (130), and wherein the base plate (110) includes a plurality of projections on a surface inside the groove (130).