Symmetrical Flexible Light Strip Structure for 3D Bending
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Solution Overview
Problem
Existing light strips lack flexibility and structural integrity, particularly in forming three-dimensional shapes, due to internal rigidity and asymmetrical designs that can lead to electrical connection failures and limited curvature.
Innovation Solution
A symmetrical flexible printed circuit with fins on both sides, connected to supports, allowing for uniform bending on multiple planes without compromising electrical connections, and a manufacturing method that includes a resin cover for protection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the light strip uses a rigid internal structure to maintain stability, then mechanical strength is improved, but flexibility and ability to form three-dimensional shapes deteriorates
Solution Approach 1:
The support structure is divided into multiple discrete supports spaced along the circuit, connected by flexible fins. This segmentation allows each segment to bend independently while maintaining overall structural integrity, enabling three-dimensional shaping without compromising electrical connections.
Solution Approach 2:
The light strip combines rigid conductive materials (circuit traces, support bases) with flexible materials (fins, encapsulating resin). This composite construction provides both mechanical strength from the rigid components and flexibility from the soft materials, allowing the strip to be bent into complex shapes.
2Ease of manufacture
If fins are positioned only on one side of the circuit, then manufacturing complexity is reduced, but structural resistance and curvability deteriorates
Solution Approach 1:
The design employs symmetrical placement of fins on both sides of the circuit, creating balanced structural resistance. This symmetrical configuration allows the light strip to bend uniformly in any direction without compromising electrical connections or structural integrity.
3Reliability
If welds and connections are used to connect fins to the printed circuit, then electrical connection is ensured, but manufacturing complexity and risk of interruption increase
Solution Approach 1:
The fins are integrated directly into the printed circuit structure, merging the connection function into the circuit itself. This eliminates the need for separate welds or connections, reducing manufacturing complexity while maintaining reliable electrical connectivity through the continuous circuit material.
Data Source
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AI summary
Light strip (10) comprising: a flexible printed circuit (11) provided with a series of supports (12) located in sequence in a longitudinal direction (Y); one or more light sources (13) positioned on said supports (12); a profile (14) for containing said flexible printed circuit (11); and a cover (15).