Polyhedral Metal PCB Stepped Grooves for LED Lamp Bending
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Solution Overview
Problem
Conventional metal PCB assemblies for car lamps are difficult to install on geometric shapes, suffer from reliability issues due to non-standard bending processes, and are prone to cracking, which complicates achieving accurate angle adjustments and heat transfer.
Innovation Solution
A metal PCB with a polyhedral shape and a method for manufacturing that involves forming stepped grooves on the base and cells to allow for accurate bending, heat transfer, and angle adjustment, using aluminum materials with specific thermal resistance and thickness, and a back plate for support, enabling the formation of continuous reflection surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal PCB assembly is used with flat base and non-standard bending, then manufacturing is simpler, but reliability deteriorates due to cracking and deformation
Solution Approach 1:
The patent applies preliminary action by pre-forming standardized stepped grooves on the metal PCB base before the bending process. These grooves are positioned at predetermined locations and depths to guide the bending operation, ensuring that the bending force is distributed evenly and prevents cracking during assembly.
Solution Approach 2:
The patent changes the physical parameters of the metal PCB by introducing standardized stepped grooves with specific dimensions (depth, width, spacing) into the base structure. This parameter modification allows the material to bend predictably at controlled locations without cracking, resolving the reliability issue while maintaining manufacturing feasibility.
2Manufacturing precision
If metal PCB is bent without standardized grooves, then manufacturing process is simpler, but manufacturing precision deteriorates due to inaccurate angle adjustments
Solution Approach 1:
The patent segments the continuous metal PCB base into distinct sections by introducing stepped grooves at specific intervals. This segmentation creates predetermined bending zones that guide the forming process, enabling precise angle adjustments for each section while maintaining overall structural integrity.
Solution Approach 2:
The standardized stepped grooves are pre-formed on the base before the bending operation. This preliminary action establishes exact bending locations and angles, ensuring manufacturing precision without requiring complex real-time adjustments during the forming process.
3Adaptability or versatility
If conventional flat metal PCB is used, then device complexity is lower, but adaptability deteriorates because it cannot be installed on geometric shapes
Solution Approach 1:
The patent introduces curvature and geometric forms into the previously flat metal PCB base by forming stepped grooves that create polyhedral shapes. This allows the base to be bent into various geometric configurations (cones, cylinders, polyhedrons) to match different installation surfaces, significantly improving adaptability while maintaining reasonable structural complexity.
Solution Approach 2:
The patent transitions the metal PCB from a two-dimensional flat structure to a three-dimensional polyhedral structure by forming stepped grooves that enable bending in multiple directions. This dimensional change allows the base to conform to various geometric installation surfaces, enhancing versatility.
4Temperature
If non-standard bending process is used, then ease of manufacture is higher, but heat transfer deteriorates due to deformation and cracking
Solution Approach 1:
The patent modifies the base structure parameters by introducing standardized stepped grooves with optimized dimensions that control the bending process. This ensures uniform stress distribution during bending, preventing deformation and cracking that would compromise heat transfer pathways in the metal PCB.
Solution Approach 2:
The stepped grooves are pre-formed to establish controlled bending zones before the actual bending operation. This preliminary preparation ensures that the bending process proceeds uniformly without creating defects that would interrupt heat transfer, maintaining thermal efficiency while simplifying the manufacturing process.
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
The solution allows for accurate bending and heat transfer while minimizing product damage, achieving precise angle adjustments and preventing deformation, thus enhancing the reliability and flexibility of the LED lamp module.
Implementation Method 1
a base (130) having conductive patterns (110) formed on top thereof
Implementation Method 2
the base (130) has a plurality of base stepped grooves (135) concavely shaped unitarily with the underside where no conductive patterns are formed
Data Source
AI summary
An LED lamp having a metal PCB bent polyhedrally and a method for manufacturing the LED lamp is provided, where a base constituting the metal PCB has a rectangular or geometric shape and is configured to have a plurality of base stepped grooves formed spaced apart from each other on the underside thereof in such a manner as to be bent upward or downward from the base to form reflection surfaces continuously, so that at the time when both ends of the base come into contact with the plane, the base has a geometric shape in which the base is located in space through the reflection surfaces continuously arranged.