Resin-Embedded LED Lighting Device with Flexible PCB
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Solution Overview
Problem
Conventional lighting devices with light guide plates are limited in thickness reduction, flexibility, and design freedom due to the rigid nature of the plates, which hinders the creation of thin and aesthetically pleasing products with uniform light distribution.
Innovation Solution
The use of a resin layer instead of a light guide plate to guide light from LEDs, combined with a flexible printed circuit board and protruding optical patterns, allows for a thinner design, improved flexibility, and enhanced light reflection and diffusion, enabling geometric optical patterns and uniform surface lighting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a light guide plate is used to guide light and provide uniform luminance, then light distribution uniformity is improved, but the overall thickness of the lighting device increases
Solution Approach 1:
The patent removes the light guide plate from the lighting device structure, extracting this component that caused thickness increase while maintaining uniform light distribution through alternative means (direct LED arrangement and reflective housing design)
Solution Approach 2:
The patent combines multiple functions into the housing structure: the housing serves as both the structural enclosure and the light-guiding element with reflective inner surfaces, eliminating the need for a separate light guide plate
2Illumination intensity
If a light guide plate is used to uniformly transmit light, then light uniformity is improved, but the device loses flexibility and design freedom
Solution Approach 1:
The patent employs a flexible printed circuit board to carry LED components, enabling the lighting device to be bent or shaped according to various design requirements while maintaining electrical connectivity and light uniformity
Solution Approach 2:
The lighting device structure is designed to be adaptable and reconfigurable, allowing different arrangements of LEDs and reflective surfaces to achieve various lighting patterns and uniformity levels across different applications
3Illumination intensity
If a light guide plate is used to improve luminance and uniformity, then optical performance is improved, but the device complexity and number of components increase
Solution Approach 1:
The patent removes the light guide plate component entirely, reducing the total number of parts while achieving the same optical performance through a simplified structure consisting of LEDs mounted on a flexible circuit board with a reflective housing
Solution Approach 2:
The housing structure performs multiple functions simultaneously: it provides mechanical enclosure, acts as a light guide through reflective inner surfaces, and enables heat dissipation, thereby eliminating the need for separate dedicated components
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 reduces the overall thickness of lighting devices, enhances aesthetic appeal, improves light uniformity, and allows for more flexible product designs, including curved surfaces, while maintaining reliable component alignment and optical properties.
Implementation Method 1
a resin layer 150 which is formed on the light emitting units 130 so that the light emitting units 130 are embedded in the resin layer, and guides emitted light forward
Implementation Method 2
guides emitted light forward
Implementation Method 3
a protruding optical pattern is formed in an inner part of the lighting device so that emitted light forms various patterns
Implementation Method 4
improves light uniformity
Data Source
Figure 1~4
Figure 5~7
Figure 8~9
AI summary
Provided is a lighting device, including: one or more light emitting units formed on a printed circuit board; a resin layer which is formed on the light emitting units so that the light emitting units are embedded in the resin layer; and a diffusion member formed on an upper side of the resin layer, wherein a protruding optical pattern is formed on at least one of an upper side of the printed circuit board and a lower surface of the diffusion member, whereby various geometric optical patterns can be implemented, an entire thickness can be reduced and when a product is designed, a degree of freedom in design can be improved according to the securing of flexibility.