Segmented LED Lighting Module Cutting Flexibility
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Solution Overview
Problem
Existing lighting devices with elongated substrates and distributed light radiation sources face limitations in flexibility and cost-effectiveness when cutting to length, particularly in low-flux and low-cost modules, due to increased costs, reduced efficiency, or the need for additional user operations to close circuits.
Innovation Solution
Incorporating intermediate cutting lines and Zener diodes within the lighting device's circuit allows for finer resolution cutting of light radiation sources, maintaining electrical connectivity and reducing the need for external components, while maintaining protection levels and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the application pitch of light sources is reduced to enable finer cutting resolution, then the flexibility in choosing module length is improved, but the number of light sources per unit length increases leading to higher cost
Solution Approach 1:
The patent divides the lighting module into multiple independently controllable segments, each with its own current regulator. This allows the module to be cut at segment boundaries without affecting the functionality of remaining segments, enabling flexible length adjustment without reducing the pitch between light sources.
2Adaptability or versatility
If the power supply voltage is reduced to decrease the number of light sources per unit, then the unit length is reduced enabling finer cutting, but the efficiency of the module decreases due to increased voltage drop across the current regulator
Solution Approach 1:
By segmenting the module so each unit contains its own current regulator and a manageable number of LEDs, the system can operate at higher voltages (24V or 48V) without excessive voltage drop. Each segment is self-contained and can be independently optimized, allowing efficient operation while maintaining cutting flexibility.
Solution Approach 2:
The patent introduces the dimension of modular segmentation, transforming the problem from adjusting voltage to achieve cutting flexibility to adjusting segment boundaries. This allows the system to maintain optimal voltage levels for efficiency while achieving flexible length adjustment through physical segmentation.
3Adaptability or versatility
If multi-chip light radiation sources are used to reduce the number of sources per unit, then the unit length is reduced, but the cost increases and efficiency may be negatively impacted
Solution Approach 1:
Instead of using expensive multi-chip LEDs to reduce unit length, the patent segments the module into multiple units, each containing standard single-chip LEDs with their own current regulator. This achieves the same effect of reducing sources per unit through spatial segmentation rather than using costly multi-chip components.
4Adaptability or versatility
If cutting lines with contacts are provided to enable user cutting, then the flexibility in choosing module length is improved, but additional user operations are required to close the circuit
Solution Approach 1:
The module is segmented into independently functional units, each with complete electrical circuits including current regulators. When cut at segment boundaries, each remaining segment has self-contained circuits that automatically function without requiring external closing elements or additional user operations to complete electrical paths.
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 enhances user flexibility in choosing module length, reduces additional user operations, and maintains protection integrity, with minimal impact on overall efficiency and cost, even in protected modules.
Implementation Method 1
providing, in the individual electrical unit, at least one Zener diode arranged with the cathode coupled to a node located in an intermediate position between the plurality of sets of light radiation sources and the anode coupled to another node
Data Source
Figure 1
Figure 2~3
AI summary
A lighting device comprises an elongated support member (102) with a sequence of consecutive segments having a first end (10A) and a second end (10B), and light radiation sources (e.g. LEDs) distributed along the support member (102) in a sequence of electrical units (10) arranged at respective segments of the support member. The electric units (10) comprise a plurality of sets of electrically-powered light radiation sources (D11, D12, D13; D21, D22, D23; D11, D12, D13, D21; D22, D23), electrically arranged in series between a first (LED+) and a second (LED-) power supply node. At least one set (D21, D22, D23; D22, D23) of light radiation sources can be separated from the electrical unit (10) at a cutting line (LC1, LC2) intermediate between the first end (10A) and the second end (10B) of the respective segment of the support member. An electrically-conductive path (12, 13) parallel to the aforesaid separable set (D21, D22, D23; D22, D23) can be activated by separating this set (D21, D22, D23; D22, D23) from the electric unit (10) so as to maintain the electrical coupling between the first (LED+) and the second (LED-) power supply node.