Modular LED Lighting Panels with Snap Connectors
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Solution Overview
Problem
Current LED-based backlighting systems for translucent panels or signs face challenges such as large thickness due to high current requirements, inefficient diffusion leading to glare, and the need for extensive heat management systems, making them bulky and complex, while also being difficult to customize for various installations.
Innovation Solution
The development of a flexible lighting system using modular light sheets with snap connectors for mechanical and electrical interconnection, allowing for customizable configurations and efficient power distribution, which includes a substrate with light-emitting elements connected by conductive traces and frame elements for support and reduced electrical resistivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If high current LEDs are used to provide bright light sources, then illumination intensity is improved, but the system thickness increases due to larger heat sinks and thermal management systems
Solution Approach 1:
The patent divides the lighting system into multiple low-current LED segments distributed across the panel rather than using fewer high-current LEDs. This segmentation allows for reduced thermal management requirements per LED, enabling thinner heat sinks and overall system thickness reduction while maintaining total illumination intensity through the additive effect of multiple LED sources.
2Device complexity
If LEDs are spaced several inches apart to reduce quantity, then device complexity is reduced, but illumination uniformity deteriorates requiring larger diffusers that decrease efficiency
Solution Approach 1:
The patent changes the key parameter from LED spacing to LED current distribution. By using many low-current LEDs in a dense arrangement rather than few high-current LEDs spaced apart, the system achieves both good illumination uniformity (due to dense distribution) and acceptable complexity levels. The diffuser size is optimized for this specific LED configuration to maintain high diffusion efficiency.
3Adaptability or versatility
If custom sizing is implemented to fit particular locations, then adaptability is improved, but manufacturing cost increases for non-modular systems
Solution Approach 1:
The patent employs a modular design where the lighting panel is divided into standardized reusable components (LED modules, driver modules, frame sections) that can be configured in different arrangements. This segmentation enables custom sizing and shape adaptations for different installation locations while maintaining cost-effectiveness through repeated use of standardized modules, avoiding the need for custom manufacturing for each installation.
4Stability of the object's composition
If rigid circuit boards are used to support LEDs, then structural stability is improved, but system flexibility and ease of installation deteriorate
Solution Approach 1:
The patent divides the rigid circuit board into separate modular components: a stable frame structure for structural support and separate LED module assemblies that can be independently handled and installed. This segmentation allows the frame to provide structural stability while the modular LED modules can be easily installed and reconfigured, improving ease of installation without sacrificing overall structural integrity.
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 enables a thin, efficient, and uniformly illuminated lighting system that is easy to install and customize, maintaining high efficiency and uniformity while reducing bulk and complexity, allowing for flexible mounting and electrical connectivity.
Implementation Method 1
a first plurality of light-emitting elements disposed on the first substrate and electrically connected to the first and second power conductors
Implementation Method 2
first and second spaced-apart power conductors disposed on the first substrate... electrically connected to the first and second power conductors
Data Source
Figure 1A~1E
Figure 2A~2B
Figure 2C~2E
AI summary
In accordance with various embodiments, a modular lighting system features multiple light panels each having multiple light-emitting elements thereon, as well as connectors for electrically and mechanically interconnecting the light panels. A lighting system comprises a first light panel comprising a first substrate, first and second spaced-apart power conductors disposed on the first substrate, a plurality of first light-emitting elements disposed on the first substrate and electrically connected to the first and second power conductors, a first snap connector electrically connected to the first power conductor, and a second snap connector electrically connected to the second power conductor, and a second light panel comprising a second substrate, third and fourth spaced-apart power conductors disposed on the second substrate, a plurality of second light-emitting elements disposed on the second substrate and electrically connected to the third and fourth power conductors, a third snap connector electrically connected to the third power conductor, and a fourth snap connector electrically connected to the fourth power conductor, wherein (i) the first snap connector is configured for connection to the third snap connector, thereby electrically coupling the first power conductor to the third power conductor, and (ii) the second snap connector is configured for connection to the fourth snap connector, thereby electrically coupling the second power conductor to the fourth power conductor.