LED Bar Module Thermal Conduction and Calibration
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Solution Overview
Problem
Existing LED bar modules face challenges with efficient cooling, electrical isolation, and calibration data storage, particularly in humid environments where corrosion and ground faults can occur, and are complex to manufacture and maintain.
Innovation Solution
The LED bar module incorporates a pixel board with a memory circuit for storing LED calibration data close to the LEDs, allowing for intelligent calibration and recalibration, and features a humidity valve and heat conductive design to prevent corrosion and improve cooling, with replaceable boards and adjustable diffusers for varying beam angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LEDs are placed in a housing with internal power and data lines, then the housing can be sealed to prevent moisture entry, but the risk of ground faults increases due to potential current jumps from high voltage lines to the housing
Solution Approach 1:
The patent introduces an intermediary barrier layer (protective coating or isolation layer) between the high voltage power lines and the housing. This intermediary prevents direct contact and potential current jumps to the housing while allowing the housing to remain sealed for moisture protection. The intermediary acts as a protective mediator that resolves the contradiction between sealing and ground fault prevention.
Solution Approach 2:
The patent extracts the high voltage power lines from direct proximity to the housing by routing them through isolated channels or conduits within the housing structure. This separation removes the harmful interaction between the high voltage lines and the housing while maintaining the sealed environment for moisture protection.
2Reliability
If the housing is sealed to prevent moisture entry, then corrosion is prevented, but manufacturing complexity increases due to the need for precise sealing
Solution Approach 1:
The patent employs flexible sealing elements such as gaskets, O-rings, or adhesive films that can be easily integrated into the housing structure. These thin film or flexible sealing elements provide effective moisture protection while being simple to manufacture and install, avoiding the complexity of precision mechanical sealing arrangements.
Solution Approach 2:
The patent uses simple, inexpensive sealing materials such as adhesive tapes, paint, or basic gaskets that can be easily applied during manufacturing. These simple sealing solutions provide adequate moisture protection without requiring complex sealing mechanisms, thereby maintaining ease of manufacture while preventing corrosion.
3Quantity of substance
If calibration data is stored remotely from the LEDs, then storage capacity is sufficient, but data accuracy decreases due to potential mismatch between calibration data and specific LED characteristics
Solution Approach 1:
The patent implements a nested storage structure where calibration data is stored in memory elements positioned in close proximity to the LEDs within the same module or housing. This nested arrangement allows sufficient storage capacity while ensuring that the calibration data remains associated with and accurate for the specific LED characteristics, resolving the contradiction between storage capacity and calibration accuracy.
4Ease of manufacture
If the LED bar is designed for fixed orientation, then manufacturing is simplified, but adaptability to different installation orientations is reduced
Solution Approach 1:
The patent designs the LED bar with universal mounting features and symmetric electrical connections that allow the same manufactured unit to be installed in multiple orientations. The housing and mounting structure are designed to accommodate various installation angles and positions, providing multi-functionality that maintains manufacturing simplicity while enhancing adaptability to different installation requirements.
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
This solution ensures efficient cooling, electrical isolation, and accurate calibration of LEDs, reducing the risk of ground faults and corrosion, while simplifying manufacturing and maintenance, and allowing for flexible beam angle adjustments.
Implementation Method 1
the pixel board conducts heat from the LEDs
Implementation Method 2
the pixel board comprises a memory circuit, in which memory circuit LED calibration data for the LEDs at the board is stored
Data Source
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AI summary
The present invention relates to LED bar modules (2) where the LED groups are placed at a pixel board (6). The present invention further concerns a method for calibration of LEDs. It is the object of the invention to achieve a highly efficient LED bar for generating a bar of light. A further object of the invention is to store calibration data for each LED both electrically and mechanically close to the actual LED. Preferably, the main printed circuit is placed inside a heat conductive tube (4), where the pixel board (6) is placed outside the heat conductive tube (4) in a longitudinal recess, where the main printed circuit is placed inside an isolation cover (12). Hereby, it is achieved that the LEDs are placed on the outside of the tube (4) in a way where heat generated from the LEDs is conducted downwards to the tube (4). Inside the tube (4), the rest of the power electronics and also the light controlling electronics are placed.