Silicone LED Lighting Kit for Curved Surfaces
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Solution Overview
Problem
Existing lighting systems struggle to provide continuous, uniform light on curved surfaces due to visible seams and discontinuities caused by connectors, and are cumbersome to repair or replace.
Innovation Solution
A lighting kit using elongate extruded silicone rubber support profiles with a printed circuit board and a connecting piece made of transparent silicone rubber, where the connectors are positioned to avoid the seam and allow seamless light diffusion, and components are easily replaceable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If known LED fittings with connectors are used to span great lengths, then the lighting system can cover longer distances, but visible seams and discontinuities appear at the connector zones
Solution Approach 1:
The patent extracts the connector elements (cable bushing elements and welding wires) from the visible light-emitting zone by positioning them at the rear side of the support profile, behind the diffusing upper wall. This separation allows the lighting system to maintain continuous light emission across connected modules while still enabling electrical connections between printed circuit boards.
Solution Approach 2:
The patent resolves the contradiction by moving the connector elements from the front light-emitting dimension to the rear structural dimension. The cable bushing elements are positioned at the rear side of the support profile, and welding wires are routed through channels in the diffusing wall, effectively relocating potential discontinuities to a non-visible dimension while maintaining light continuity in the visible dimension.
2Strength
If rigid steel or aluminium profiles are used for LED fittings, then structural strength is improved, but adaptability to curved surfaces deteriorates
Solution Approach 1:
The patent replaces rigid steel or aluminium profiles with a support profile made of elastomeric material (such as silicone rubber). This flexible support profile can be bent and shaped to adapt to curved building surfaces while maintaining structural integrity. The elastomeric material provides both the necessary mechanical strength and the flexibility required for curved surface installation.
Solution Approach 2:
The support profile is constructed as a composite structure with a core made of elastomeric material for flexibility, combined with integrated functional elements such as channels for wiring and mounting features. This composite approach maintains structural strength while enabling adaptability to curved surfaces.
3Reliability
If connectors are positioned at the seam zone to provide power and control, then electrical connection is achieved, but light discontinuity occurs at the connecting seam
Solution Approach 1:
The patent extracts the cable bushing elements from the front light-emitting zone and positions them at the rear side of the support profile. This allows electrical connections to be made without creating visible discontinuities in the light emission, as the connectors are located in a non-visible zone behind the diffusing upper wall.
Solution Approach 2:
The patent relocates the electrical connection elements from the visible light-emitting dimension to the hidden rear structural dimension. The cable bushing elements are positioned at the rear side, and wiring channels are provided within the diffusing wall, effectively separating the electrical connection function from the light emission function in different spatial dimensions.
4Reliability
If entire lighting appliances are replaced in case of damage, then system reliability is maintained, but repair ease and time consumption worsen
Solution Approach 1:
The patent divides the lighting system into separable modular components: the support profile, the printed circuit board with light-emitting diodes, and the cable bushing elements. This segmentation allows individual components to be replaced independently rather than replacing the entire lighting appliance, facilitating easier and faster repairs while maintaining system reliability.
Solution Approach 2:
The patent employs a nested structure where the printed circuit board is housed within the support profile, and cable bushing elements are integrated into the support profile structure. This nesting allows for systematic disassembly and replacement of components at different levels, enabling repair of specific failed components without disturbing the entire system.
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 kit provides a continuous, uniform light emission with minimal visible seams and allows for easy replacement of damaged parts, ensuring consistent lighting on both flat and curved surfaces.
Implementation Method 1
a light source, preferably in the form of a printed circuit board with light-emitting diodes
Implementation Method 2
the upper wall is configured to diffuse the light originating from the light-emitting diodes
Data Source
Figure 1~2
Figure 3
Figure 4~6
AI summary
Lighting kit (1) configured to be attached to a support surface (5), wherein the kit (1) comprises at least a printed circuit board (2) comprising light-emitting diodes and at least a first and second elongate extruded support profile (3) made of silicone rubber, wherein the lighting kit (1) furthermore comprises coupling means which are configured to connect juxtaposed support profiles (3) to each other, wherein a connecting seam is formed between adjoining support profiles in the connected position, characterized in that said printed circuit board (2) is enclosed by a housing (12) made of silicone rubber, wherein said housing (12) comprises cable bushing elements (11) which are non-releasably arranged at the location of the ends of the housing (12), which cable bushing elements (11) are configured to electrically connect the printed circuit boards (2) of juxtaposed support profiles (3) to each other,wherein each support profile comprises a receiving cavity (4) which extends in the longitudinal direction of the support profile (3) and which is configured to accommodate said housing (12) with the printed circuit board (2), so that one part of the housing (12) extends in the receiving cavity of the first support profile and the other part of the housing (12) extends in the receiving cavity of the second support profile.