Expandable LED Light Bar System for Retrofitting
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Solution Overview
Problem
The existing light box signs with fluorescent tubes pose environmental hazards and require frequent maintenance, and retrofitting with LED light bars is challenging due to the lack of industry standards for shape and size, necessitating custom fabrication or physical modification.
Innovation Solution
An expandable light bar system comprising modular segments with LED lighting units, an expansion adaptor for adjustable length, and endcaps compatible with existing fluorescent sockets, allowing for easy integration into various light box sizes without custom fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fluorescent tubes are used in light box signs, then the signs can be manufactured with conventional components, but they pose environmental hazards and require frequent maintenance
Solution Approach 1:
The patent replaces fluorescent tubes with LED light bars that have significantly longer operational lifetimes. The LED light bars are designed as replaceable modules that can be easily installed and removed, allowing for maintenance without replacing entire light box assemblies. This addresses the environmental hazard and maintenance frequency issues while maintaining ease of manufacture through standardized components.
2Use of energy by moving object
If LED light bars are used to replace fluorescent tubes, then energy efficiency and environmental friendliness improve, but retrofitting is challenging due to lack of industry standards requiring custom fabrication
Solution Approach 1:
The patent designs LED light bars with standardized mounting interfaces and dimensions that can be adapted to fit various light box sizes and configurations. The light bars incorporate universal mounting brackets and adjustment mechanisms that allow installation in different orientations and positions, eliminating the need for custom fabrication for each retrofit application while maintaining energy efficiency benefits.
Solution Approach 2:
The LED lighting system is divided into modular light bar segments that can be individually selected and combined to match the required length and configuration for different light box applications. This segmentation allows for flexible adaptation to various sizes without custom fabrication, as standard segments can be joined together or selected alone to fit the specific retrofit needs.
3Adaptability or versatility
If custom light bars are fabricated for each light box, then perfect fit and customization are achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent incorporates adjustable mounting mechanisms and flexible positioning features in the LED light bars that allow field adjustment to achieve perfect fit in various light box configurations. The mounting brackets can be positioned at different locations and angles, and the light bars can be adjusted during installation to accommodate slight variations in light box dimensions, providing customization without requiring complex custom fabrication processes.
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 efficient and environmentally friendly LED lighting solutions with adjustable length and compatibility with standard light box sizes, reducing maintenance needs and costs while avoiding physical modifications.
Implementation Method 1
Each of the lighting units can include a housing for supporting a plurality of light emitting diodes
Data Source
AI summary
An expandable light bar system includes a plurality of light bar segments each having an elongated hollow body and a lighting unit. Each lighting unit includes a housing with a plurality of light emitting diodes that are electrically connected to either a subsequent lighting unit or a power source. The housing is secured onto a ridge that is located along the top surface of the elongated body. An expansion adaptor is positioned between two light bar segments and allows the overall length of the joined light bar segments to be adjustable. A spacer is positioned at the center of the adaptor and defines a minimum separation distance between the segments. A pair of endcaps are removably secured to one end of each of the light bar segments and are configured to engage an existing fluorescent high output socket within a light box to support placement of the joined segments.