Segmented PCB Finger Design for LED Module Cost Reduction

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Solution Overview

Problem

The high cost of printed circuit boards (PCBs) in luminaires, particularly due to material usage and assembly, and the challenge of achieving uniform light distribution with existing designs.

Innovation Solution

A PCB design featuring multiple finger portions with longitudinal protrusions and two rows of light emitting elements, allowing for reduced material usage and efficient assembly while ensuring uniform light distribution through strategic placement of elements on protrusions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If large PCBs are used to decrease the number of PCBs required, then the amount of cables and connections is reduced, but the PCB material cost increases

Engineering Contradiction:

Improvenumber of PCBs and connectionsVSAvoidPCB material area

Core Design Contradiction:

Device complexityVSArea of stationary object

Solution Approach 1:

The PCB is divided into a base portion and multiple finger portions extending in a transversal direction. Each finger portion contains light emitting elements arranged in rows, allowing the PCB to be segmented into functional units that can be optimized for both material usage and light distribution.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The finger portions are designed with apertures having shapes corresponding to the finger portions themselves. These apertures allow nested PCB designs where multiple PCB layouts can be efficiently arranged on a manufacturing panel, reducing material waste while maintaining functional requirements.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Reliability

If light emitting elements are arranged with distance from edges to meet creepage requirements, then safety is ensured, but the pitch between elements on different finger portions becomes larger than on the same finger portion, affecting uniformity

Engineering Contradiction:

Improvecreepage distanceVSAvoiduniformity of pitch between light emitting elements

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

Longitudinal protrusions are added to specific locations on the finger portions where light emitting elements are mounted. These protrusions create localized mounting positions that allow precise control of element placement, ensuring both adequate creepage distances and uniform pitch across different finger portions.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The design transitions from a flat PCB surface to a three-dimensional structure with longitudinal protrusions extending from the finger portions. This dimensional change provides additional mounting positions that resolve the conflict between creepage requirements and pitch uniformity by elevating elements to specific heights and positions.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Data Source

PatentEP2873310B1Optimized printed circuit board

Publication Date: 2019.02.27 SIGNIFY HOLDING BV

Figure 1a~1b
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Figure 3a~3b

AI summary

The present invention relates to a printed circuit board (100, 200) comprising several finger portions (102, 103, 104) projecting from a base portion (101), wherein each finger portion is provided with a plurality of light emitting elements (106). By means of the invention it is possible to optimize the physical size of the printed circuit board (100, 200) such that a resulting LED module requires less printed circuit board area per thereon arranged LED, thereby decreasing the cost of the overall LED module.