U-Shaped Diffuser Profile for Flexible LED Arrays
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Solution Overview
Problem
Existing solid-state lighting devices face challenges due to the requirement of a channel-shaped profile, multiple gluing processes, and inflexible diffuser elements, which limit scalability and efficiency.
Innovation Solution
A method involving a compliant adhesive layer and a single diffuser element with adjustable thickness and light propagation properties, allowing for single-module cutting and scalable production of flexible lighting modules with improved light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a channel-shaped profile with multiple gluing processes is used, then the lighting device achieves proper structure and light diffusion, but the manufacturing complexity and production time increase
Solution Approach 1:
The patent merges the channel-shaped profile and diffuser element into a single integrated component. The U-shaped profile serves both structural support and light diffusion functions through its translucent material, eliminating the need for separate gluing processes to attach diffuser layers. This consolidation reduces manufacturing steps while maintaining both structural integrity and light diffusion performance.
Solution Approach 2:
The U-shaped profile is designed to perform multiple functions simultaneously: it provides mechanical support for the PCB, acts as a light guide, and serves as the diffuser element. The translucent material of the profile enables light diffusion without requiring additional diffusive layers, making the component universal in its functionality.
2Illumination intensity
If multiple gluing processes are employed for transparent material and diffusive layer, then proper light transmission and diffusion are achieved, but production efficiency decreases
Solution Approach 1:
The patent combines the light transmission and diffusion functions into a single U-shaped profile component made of translucent material. This eliminates the need for separate transparent material and diffusive layer gluing processes, reducing production steps from two to one while maintaining both light transmission quality and diffusion effectiveness.
3Ease of manufacture
If fixed-thickness diffuser elements are used, then manufacturing is simplified, but adaptability to different application requirements is reduced
Solution Approach 1:
The patent enables dynamic adjustment of the diffuser element thickness by modifying the height of the U-shaped profile itself. Since the profile serves as both structure and diffuser, varying its cross-sectional dimensions allows customization of diffusion characteristics for different applications without complicating the manufacturing process.
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
Enables high parallelization, reduced production steps, and adaptable diffuser elements that enhance light diffusion and emission efficiency, while providing protection and scalability in lighting device design.
Implementation Method 1
a second layer of adhesive material is applied on the light emission module and/or on the diffuser element
Implementation Method 2
a diffuser element is coupled to the support member and to the array of light radiation sources via at least one gluing process
Data Source
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AI summary
Lighting devices, e.g. "flex" lighting devices, are produced: - by providing a support substrate (10) with electrically powered light radiation sources (12), e.g. LED sources, in a plurality of linear arrays arranged side-by-side; - by sealingly coupling to the support substrate (10), e.g. via a thixotropic viscous adhesive (16), a light-propagating element (20) having cavities (200) for receiving therein said light radiation sources (12), and - by cutting (C) the support substrate (10) with the light-propagating element (20) sealingly coupled therewith intermediate the linear arrays of light radiation sources (12), in order to produce a plurality of linear lighting devices.