Multi-Plane LED Mounting on Flexible PCB for UL 1638 Light Patterns
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Solution Overview
Problem
Existing visual alarm devices that comply with standards like UL 1638 often require complex lens and reflector arrangements, increasing costs and complexity.
Innovation Solution
A system for mounting LEDs in multiple planes on a single flexible PCB, eliminating the need for reflectors or lenses by orienting LEDs in various directions using a rigid frame, which can be mounted to a wall or ceiling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single light source with lenses and reflectors is used to achieve compliant light patterns, then the light pattern compliance is improved, but the device complexity and cost increase
Solution Approach 1:
The invention divides the light source into multiple LED elements (typically 3-4 LEDs) arranged in different orientations rather than using a single light source. Each LED emits light in a specific direction, and collectively they produce the required light pattern without needing complex optical components. This segmentation approach simplifies the overall device structure while maintaining compliance with UL 1638 standards.
Solution Approach 2:
The invention arranges LEDs in multiple spatial dimensions and orientations (different planes and angles) to achieve three-dimensional light distribution. By positioning LEDs at various angles (e.g., 0°, 45°, 90°, 135°) and mounting them on flexible PCBs that can be configured in different orientations, the system creates a multi-dimensional light pattern that complies with standards without requiring traditional optical elements.
2Manufacturing precision
If a single light source with lenses and reflectors is used to achieve compliant light patterns, then the light pattern compliance is improved, but the cost increases
Solution Approach 1:
The invention extracts and removes the expensive optical components (lenses and reflectors) from the system by using multiple LEDs with built-in directional emission characteristics. The LEDs themselves provide the necessary light directionality through their physical orientation and mounting configuration, eliminating the need for additional optical elements and reducing manufacturing costs while maintaining light pattern compliance.
Solution Approach 2:
The invention replaces expensive, precision-machined optical components with inexpensive LED elements and simple mounting structures. The flexible PCBs and basic reflectorless design use lower-cost materials and manufacturing processes, making the overall device more cost-effective while achieving the same functional outcome of compliant light pattern emission.
3Device complexity
If LEDs are mounted in multiple planes on a flexible PCB, then the need for reflectors or lenses is eliminated, but the mounting complexity increases
Solution Approach 1:
The invention uses flexible PCBs that can be bent and configured into different shapes and orientations to accommodate multiple LED mounting planes. The flexibility of the PCB allows it to be molded to fit various housing configurations and to position LEDs at different angles without requiring complex rigid structural components. This dynamic flexibility simplifies the overall mounting process compared to creating precise rigid structures for multi-plane LED installation.
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
Reduces costs and simplifies the design while maintaining compliance with UL 1638 light patterns without the need for additional optical components.
Implementation Method 1
a plurality of light emitting diodes (LEDs) for a visual alarm device in multiple planes on a single printed circuit board (PCB)
Data Source
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AI summary
Systems and methods for mounting light emitting diodes for a visual alarm device in multiple planes are provided. The visual alarm device can include a plurality of light emitting diodes (LEDs) mounted on a printed circuit board and configured to flash during an emergency situation, wherein each of the plurality of LEDs can be mounted in a respective one of a plurality of planes.