Method of assembling a lighting device with flexible circuits having light-emitting diodes positioned thereon
View Patent ↗A method of assembling a lighting device that has a base, an optic defining an optical chamber, a driver circuit positioned in electrical communication with the base, and a flexible circuit board positioned within the optical chamber along and generally circumscribing a longitudinal axis of the optical chamber and in electrical communication with the driver circuit. The flexible circuit board may comprise a plurality of longitudinal sections. Each longitudinal section may comprise a first inclined section, a second inclined section, and a plurality of light-emitting diodes (LEDs). The first inclined section may be positioned in the direction of the base relative to the second inclined section. The lighting device may further include a longitudinal translation device to translate longitudinally part of the flexible circuit board.
1. A method of assembling a lighting device having a base, an optic having an inner surface defining an optical chamber, a structural member, a flexible circuit board having a plurality of LEDs positioned thereupon and being fixedly attached at a first end to the structural member, a longitudinal translation device configured to translate longitudinally a second end of the flexible circuit board, and a driver circuit, the method comprising the steps of:
positioning the structural member within the optical chamber; then
attaching the flexible circuit board to the structural member; then
positioning the flexible circuit board in a collapsed position; then
disposing the flexible circuit board within the optical chamber by passing the flexible circuit board through an aperture of the optic; then
transitioning the flexible circuit board into an expanded position by operating the longitudinal translation device; then
attaching the base to the optic; and then
positioning the driver circuit in electrical communication with the base.
2. The method of claim 1 further comprising orienting the plurality of LEDs to emit light in a direction that results in the lighting device being adapted to emit light in a selected distribution.
3. The method of claim 1 wherein the structural member is integrally formed with the optic.
4. The method of claim 1 wherein the longitudinal translation device has a generally spiraled configuration; wherein the longitudinal translation device interfaces with the structural member; and wherein the second end of the flexible circuit board is translated longitudinally by turning the longitudinal translation device.
5. The method of claim 1 wherein the flexible circuit board comprises a plurality of longitudinal sections, each longitudinal section comprising a first inclined section and a second inclined section; wherein each of the first and second inclined sections have associated therewith an LED of the plurality of LEDs; and wherein an orientation of the LED associated with each of the first and second inclined sections may be altered by operation of the longitudinal translation device; the method further comprising the step of operating the longitudinal translation device so as orient the LEDs associated with the first and second inclined sections to emit light in a direction that results in the lighting device being adapted to emit light in a selected distribution.
6. The method of claim 1 wherein the flexible circuit board is provided in a substantially flat configuration; and wherein the step of positioning the flexible circuit board in the collapsed position comprises folding the flexible circuit board so as to form a generally prismatic structure.
7. The method of claim 6 wherein the step of folding the flexible circuit board comprises folding the flexible circuit board so as to define a plurality of longitudinal sections.
8. The method of claim 7 wherein the step of folding the flexible circuit board comprises folding each of the longitudinal sections so as to define a first inclined section and a second inclined section.
9. The method of claim 1 wherein the flexible circuit board is formed into a generally cylindrical structure.
10. The method of claim 1 wherein the flexible circuit board defines a bounded region of the optical chamber; the method further comprising the step of positioning the driver circuit within the bounded region.
11. The method of claim 1 wherein the driver circuit is included on the flexible circuit board.
12. The method of claim 1 wherein the optic comprises an distal section and a proximal section; wherein the proximal section is configured to be attachable to the distal section; and wherein the aperture of the optic is defined by an opening of the distal section where the proximal section is not attached to the distal section; the method further comprising the step of attaching the proximal section to the distal section.