Luminous Module with Multi-Plane Conductor Tracks
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Solution Overview
Problem
The connection of light emitting diodes (LEDs) using cable sections is complex and expensive, particularly when attempting to connect them to complex carrier bodies in non-planar configurations, such as in luminaires or headlights with projection and reflection optical systems.
Innovation Solution
A luminous module comprising luminous units connected via conductor tracks in multiple planes and orientations on a carrier body, which can include plug connections, soldering, and electrolytic application of conductor tracks on a heat sink or flexible material, allowing flexible positioning and effective heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If light emitting diodes are connected by means of cable sections, then the LEDs can be connected to complex carrier bodies, but the connection process becomes complicated and expensive
Solution Approach 1:
The patent transitions from planar circuit board arrangements to three-dimensional spatial arrangements of luminous units. Luminous units are positioned at different heights and orientations relative to the carrier body, enabling complex lighting patterns without requiring complex cable connections. This dimensional expansion allows direct optical functionality while simplifying electrical connections.
Solution Approach 2:
The patent integrates multiple functions into the carrier body structure itself. The carrier body simultaneously serves as the mechanical support, the electrical connection substrate (with integrated conductor tracks), and the optical reference surface. This merging eliminates the need for separate cable sections and reduces connection complexity.
2Adaptability or versatility
If light emitting diodes are arranged in non-planar configurations, then the luminous applications with projection and reflection optical systems can be optimized, but the connection structure becomes more complex
Solution Approach 1:
The patent employs multi-level positioning of luminous units at different heights and angles relative to the carrier body. This three-dimensional arrangement optimizes optical performance for projection and reflection systems while the carrier body's integrated conductor tracks maintain simple electrical connections, decoupling optical complexity from electrical connection complexity.
Solution Approach 2:
Different regions of the carrier body are optimized for specific functions: some areas provide mechanical support, others serve as heat dissipation zones, and specific locations are equipped with conductor tracks for electrical connections. This localized optimization allows non-planar LED arrangements without uniformly increasing overall system complexity.
3Ease of operation
If LEDs are connected using cable sections, then individual LED connections are possible, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple LED connections into a single integrated circuit board structure with conductor tracks that simultaneously connect multiple luminous units. This eliminates the need for individual cable sections for each LED, reducing manufacturing steps and costs while maintaining the capability to individually address and control each LED through the integrated circuitry.
Solution Approach 2:
The circuit board with integrated conductor tracks automatically provides electrical connections to all luminous units during the assembly process. The conductor tracks are pre-configured to route signals to each LED position, eliminating the need for manual cable routing and connection operations, thereby reducing labor costs and manufacturing complexity.
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 solution simplifies the connection process, reduces costs, and enhances thermal linking of LEDs to a carrier body, enabling efficient and flexible use in non-planar configurations while minimizing faults and component count.
Implementation Method 1
the luminous units can be adhesively bonded, for example, onto the carrier body. An effective heat transfer to the carrier body, in particular to the heat sink, is thus advantageously ensured
Implementation Method 2
The conductor tracks can advantageously be structured on the plastic. One possibility is for the conductor tracks to be applied electrolytically on the plastic
Implementation Method 3
In particular, a laser irradiation of the surfaces can be effected beforehand, such that the conductor tracks can be applied
Implementation Method 4
at least one part of the surface of the carrier body is activated by a plasma and/or by a laser irradiation, wherein the conductor tracks can be applied in the activated region
Data Source
AI summary
A luminous module is specified comprising luminous units and a carrier body, wherein the luminous units are connected and/or contact-connected in at least two planes and/or orientations on the carrier body with conductor tracks. A method for producing the luminous module is furthermore specified.