Reflective Covering for Lighting Boards to Prevent Paint Discoloration

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Solution Overview

Problem

Existing lighting boards face issues with reduced reflectivity and non-uniform light output due to discoloration of white paint from heat during reflow soldering and the light-absorbing nature of non-white electrical components, which decreases lighting efficiency and creates shadows.

Innovation Solution

A reflective covering is applied over the electrical components on the lighting board after they have been mounted, with openings for the light emitting surfaces of the LEDs to prevent damage from heat and ensure even light distribution, using a shielding layer to protect the LEDs during application and peeling off after the reflective coating is applied.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If white paint is applied before reflow soldering to increase reflectivity, then the reflectivity is improved initially, but the paint discolors and becomes yellow after heat treatment, reducing lighting efficiency

Engineering Contradiction:

ImprovereflectivityVSAvoidpaint color stability

Core Design Contradiction:

Illumination intensityVSStability of the object's composition

Solution Approach 1:

The reflective covering is applied after the electrical components are mounted on the printed circuit board, rather than before. This sequencing ensures that the reflective covering is not exposed to the high temperatures of reflow soldering, preventing discoloration while maintaining high reflectivity for improving lighting efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses a simple sprayable reflective covering (white paint or similar material) that is applied as a final step. This disposable-like approach allows for easy application and maintains reflectivity without the complexity of heat-resistant coatings, accepting that the covering is applied after all heat treatment is complete

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Device complexity

If electrical components are mounted on the lighting board to integrate circuitry, then device complexity is reduced, but the non-white components absorb light and create non-uniform light output, reducing lighting efficiency

Engineering Contradiction:

Improvenumber of separate componentsVSAvoidlight output uniformity

Core Design Contradiction:

Device complexityVSIllumination intensity

Solution Approach 1:

The reflective covering is applied over the entire surface of the printed circuit board, including areas with electrical components. This merges the functional surface into a uniform reflective plane, causing light that would otherwise be absorbed by black components to be reflected uniformly, thereby improving light output uniformity while maintaining component integration

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent applies a white reflective covering over the entire PCB surface, changing the color appearance from the original black/non-white components to a uniform white surface. This color change transforms light-absorbing surfaces into light-reflecting surfaces, improving overall lighting efficiency and uniformity while keeping the electrical components integrated on the board

Inventive Principle:

Principle #32Color changes

3Illumination intensity

If a reflective covering is applied after components are mounted to maintain reflectivity, then lighting efficiency is improved, but additional manufacturing steps are required, increasing process complexity

Engineering Contradiction:

Improvelighting efficiencyVSAvoidmanufacturing process simplicity

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The reflective covering serves multiple functions: it provides the reflective surface for lighting efficiency, protects the electrical components from direct light exposure, and creates a uniform aesthetic appearance. This multi-functionality simplifies the overall design by eliminating the need for separate reflective shields or light traps that would otherwise be required

Inventive Principle:

Principle #25Self-service

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

This approach enhances light output efficiency by maintaining the reflective coating's integrity and preventing light blockage, while simplifying the manufacturing process by avoiding additional components and complexity.

Implementation Method 1

a reflective covering over the printed circuit board, wherein the reflective covering is provided over the set of electrical components and over the set of lighting elements, and comprises openings at least for the light emitting surfaces of the lighting elements

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS11873954B2Lighting board and luminaire using the lighting board

Publication Date: 2024.01.16 SIGNIFY HOLDING BV

AI summary

A lighting board (10), comprising: a printed circuit board (12); a set of solid state lighting elements mounted on the printed circuit board, each having a light emitting surface; a set of electrical components (16) mounted on the printed circuit board; and a reflective covering over the printed circuit board, wherein the reflective covering is provided over the set of electrical components and over the set of lighting elements, and comprises openings at least for the light emitting surfaces of the lighting elements.