Striplight Electrical Lines Joint Casting
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Solution Overview
Problem
Existing striplights with thin copper conductor tracks have high electrical resistance, limiting their length and requiring complex production methods and protective coatings, which increase complexity and cost.
Innovation Solution
A method involving a strip-shaped carrier populated with semiconductor light sources and separate, larger cross-sectional electrical lines that are jointly cast with a transparent compound, reducing electrical resistance and simplifying production by allowing flexible or rigid line arrangements and configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If thin copper conductor tracks are used on the printed circuit board, then the striplight can be flexible and compact, but the electrical resistance increases and the maximum length is limited
Solution Approach 1:
The electrical conduction function is segmented into two parts: thin copper tracks on the PCB for compact routing and flexibility, and separate thick electrical lines for low-resistance power supply. This segmentation allows each component to optimize its function without compromise.
Solution Approach 2:
The patent introduces an intermediary solution by adding separate electrical lines that work in parallel with the copper tracks. These intermediary conductors mediate between the need for compact PCB design and the requirement for low electrical resistance, enabling longer striplights without increasing overall complexity.
2Reliability
If separate electrical lines with large cross section are used, then the electrical resistance decreases and length increases, but the production complexity increases
Solution Approach 1:
The production process merges two previously separate operations into one: the electrical lines are arranged on the carrier and then jointly cast with the transparent casting compound in a single step. This combining of operations simplifies production despite the added component, eliminating the need for separate casting or encapsulation steps.
Solution Approach 2:
The electrical lines are arranged on the carrier before the casting process, performing the positioning action in advance. This preliminary arrangement allows the lines to be integrated into the final product during the standard casting operation, avoiding complex post-assembly steps.
3Reliability
If the carrier is surrounded by transparent casting compound for protection, then protection against electric shock and environment is achieved, but the production process becomes more complex
Solution Approach 1:
The protective casting and electrical line integration are merged into a single operation. The transparent casting compound simultaneously provides mechanical protection, electrical insulation, and structural integration of the electrical lines with the carrier, eliminating the need for separate protective housing or encapsulation steps.
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 method enables longer, more efficient, and cost-effective striplights with reduced complexity in production, maintaining flexibility and allowing for precise positioning of electrical lines, resulting in a compact and durable lighting solution.
Implementation Method 1
joint casting of the carrier and the at least one electrical line with an in particular transparent casting compound
Data Source
AI summary
A method for producing a striplight is disclosed. Said method utilizing at least the following steps: (a) providing a strip-shaped carrier, which is populated on at least one side with a plurality of semiconductor light sources; (b) arranging at least one electrical line on the carrier; and (c) casting the at least one electrical line on the carrier. A striplight which has: a strip-shaped carrier, populated on at least one side with a plurality of semiconductor light sources; at least one electrical line, which is arranged on the carrier; and joint casting of the carrier and the at least one electrical line, is likewise disclosed.