Off-Center LED PCB Positioning for Uniform Light Diffusion
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Solution Overview
Problem
Encapsulated linear lighting often fails to achieve a continuous line of light output due to limited light diffusion, as the light emitted from LED light engines travels a short distance before being emitted, which can result in bright spots rather than a uniform illumination.
Innovation Solution
Positioning LED light engines off-center on a long, narrow printed circuit board (PCB) within a channel, where they are adjacent to the bottom of the channel, maximizes the distance light travels before emission, enhancing diffusion by using a covering that includes diffusing additives or materials to refract and diffuse light.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If light engines are positioned centrally on the PCB, then the structure is simple and manufacturing is easy, but light diffusion is limited and bright spots appear instead of continuous light
Solution Approach 1:
The patent positions light engines off-center on the PCB, specifically at locations that maximize their distance from the outer surface of the encapsulated assembly. This asymmetric positioning arrangement causes light to travel longer distances through the encapsulating material, improving diffusion and creating a more uniform continuous light appearance rather than distinct bright spots.
2Illumination intensity
If light engines are positioned to maximize light travel distance, then light diffusion improves, but PCB layout complexity increases
Solution Approach 1:
The patent incorporates positioning features directly into the PCB structure, such as raised surfaces or designated mounting locations that guide light engine placement. These preliminary structural preparations ensure that light engines are correctly positioned during assembly to maximize light travel distance, eliminating the need for complex post-assembly adjustments and simplifying the manufacturing process.
3Illumination intensity
If encapsulating material includes diffusing additives, then light diffusion improves, but material complexity and cost increase
Solution Approach 1:
The patent modifies the optical properties of the encapsulating material by incorporating diffusing additives or selecting materials with specific refractive indices. This parameter change in the material's optical characteristics enables light diffusion without requiring complex multi-layer structures or additional optical components, achieving uniform light output through material property optimization.
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 configuration improves light diffusion, resulting in a more uniform, continuous line of light output and increased robustness against physical damage and ingress of debris, while maintaining flexibility and versatility in installation.
Implementation Method 1
encapsulating material may include diffusing additives or multiple layers of material with different optical properties to refract and diffuse light emitted from multiple LED light engines
Implementation Method 2
encapsulating material may include diffusing additives or multiple layers of material with different optical properties to refract and diffuse light emitted from multiple LED light engines
Data Source
AI summary
Encapsulated linear lighting with improved light diffusion is disclosed. The encapsulated linear lighting includes a channel and a long narrow strip of printed circuit board (PCB) with light engines disposed off-center on the PCB. The PCB is installed along a bottom inner surface of a sidewall of the channel so that the light engines are adjacent a bottom of the channel. The encapsulated linear lighting includes a covering that encapsulates and protects the PCB.