Perforated LED Illumination Sheet for Acoustic Tile Integration
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LED illumination systems for large areas face challenges in managing heat, efficiently powering devices from low-cost power supplies, and providing a cost-effective substrate for mounting LEDs, while also requiring different light spectra and intensities at various times of day for architectural lighting applications.
Innovation Solution
The development of perforated LED illumination sheets and acoustic tiles with a flexible substrate that supports an array of LEDs interconnected in parallel and series, featuring a single-layer conductor pattern and perforations to reduce substrate cost and heat management, allowing for efficient power distribution and varied light spectra.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a large number of LED devices are located in a small area to illuminate large areas, then illumination intensity is improved, but temperature rises excessively
Solution Approach 1:
The patent divides the LED array into multiple independent modules, each with its own heat dissipation path. The flexible substrate is segmented into multiple regions with individual LED clusters, allowing heat to be distributed and dissipated across larger areas rather than concentrated in one location, thus maintaining high illumination intensity while preventing excessive temperature rise.
Solution Approach 2:
The patent transitions from planar heat dissipation to three-dimensional heat management by incorporating vertical heat sinks and utilizing the flexible substrate's ability to conform to curved surfaces. This adds a vertical dimension for heat escape paths, enabling efficient heat dissipation while maintaining high LED density for strong illumination.
2Ease of manufacture
If conventional power supply systems are used for LED arrays, then power distribution is simple, but efficiency and cost-effectiveness deteriorate
Solution Approach 1:
The power supply system is segmented into multiple independent power management units, each controlling a specific LED module. This allows for localized power optimization where each unit can be tuned to operate at peak efficiency, reducing overall energy loss while maintaining manufacturing simplicity through modular assembly.
Solution Approach 2:
The patent implements dynamic parameter adjustment in the power supply system, varying voltage and current parameters based on real-time LED performance and environmental conditions. This optimizes power efficiency across different operating scenarios while using conventional power supply components, balancing simplicity with high efficiency.
3Manufacturing precision
If expensive substrates are used to mount LED devices, then manufacturing precision and thermal management are improved, but cost increases
Solution Approach 1:
The patent uses flexible thin-film substrates with integrated circuit patterns that provide precise LED mounting positions through printed conductive traces. These thin films offer sufficient mechanical precision for LED attachment while being far less expensive than conventional rigid substrates, and their flexibility enables new mounting configurations that simplify manufacturing.
Solution Approach 2:
The patent replaces traditional mechanical mounting systems with adhesive-based attachment methods on flexible substrates. This eliminates the need for complex mechanical fastening structures, reducing manufacturing cost while maintaining adequate mounting precision through surface preparation and adhesive selection.
4Adaptability or versatility
If architectural lighting requires different spectra at different times, then adaptability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple LED types with different spectral characteristics into single integrated modules. By merging red, green, blue, and white LEDs in carefully designed ratios within each module, the system achieves variable spectrum output through simple intensity control of each LED type, providing architectural adaptability without complex spectral transformation systems.
Solution Approach 2:
The patent implements dynamic spectrum adjustment by independently controlling the intensity of different LED types within each module based on time of day and application requirements. This dynamic control allows the lighting system to adapt its spectral output for different architectural lighting scenarios while using relatively simple control circuitry.
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 minimizes heat generation, reduces the need for costly cooling systems, and enables flexible light spectrum adjustment, providing a cost-effective and efficient LED lighting system suitable for architectural and acoustic applications.
Implementation Method 1
a large number of light-emitting-diode (“LED”) devices
Implementation Method 2
conductive ink electrically coupling the at least one bare LED die
Data Source
AI summary
A light system that includes one or more lighting sheets including a first lighting sheet, wherein the first lighting sheet includes a first plurality of LEDs arranged on a grid of intersecting rows and columns of electrical conductors on an insulating substrate, wherein the first plurality of LEDs emit light having a first color spectrum, wherein the first lighting sheet includes a plurality of holes through the insulating substrate of the first lighting sheet, wherein each one of the plurality of holes through the insulating substrate of the first lighting sheet is positioned between an adjacent pair of rows of electrical conductors and between an adjacent pair of columns of electrical conductors of the first lighting sheet; and an acoustic tile, wherein the first lighting sheet is mounted to the acoustic tile. Some embodiments include a plurality of layered light sheets, optionally individually controlled for color and/or brightness.