Compact LED Light Bar with Segmented Encapsulated Circuit Board
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Solution Overview
Problem
Conventional light bars used on pickup trucks face challenges due to their exposure to harsh environments, including water, contaminants, and temperature extremes, leading to short lifespans and installation difficulties in the limited space between the bumper and tailgate.
Innovation Solution
A compact, temperature, water, and contaminant-proof light bar with an extruded housing and encapsulated circuit board featuring white, amber, and red LEDs, connected via adhesively attached clips, allowing for independent control and easy installation without drilling, while providing enhanced visibility and aesthetics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional light bars are installed in the limited space between bumper and tailgate, then illumination function is provided, but lifespan is reduced due to exposure to water, contaminants, and temperature extremes
Solution Approach 1:
The light bar is divided into multiple independently controllable segments or zones, each with its own LED strings. This segmentation allows selective operation of different portions, reducing overall energy consumption and heat generation, thereby extending lifespan in harsh environments.
Solution Approach 2:
The patent employs LED technology which, while having improved lifespan compared to traditional bulbs, still benefits from the modular design where individual LED strings or segments can be replaced independently if failed, rather than replacing the entire light bar assembly.
2Volume of moving object
If light bar is made compact to fit in limited vertical space, then installation feasibility is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The light bar uses a low-profile design that extends horizontally rather than vertically, fitting within the limited vertical space between bumper and tailgate while maintaining adequate surface area for heat dissipation through the housing structure.
Solution Approach 2:
The housing incorporates specific thermal management features at critical heat-generating locations, such as heat sinks or thermally conductive materials positioned behind LED arrays, while maintaining overall compact dimensions.
3Adaptability or versatility
If light bar uses multiple LED colors and functions, then versatility is improved, but device complexity increases
Solution Approach 1:
The light bar incorporates distinct segments for different functions (brake lights, turn signals, reverse lights, auxiliary lights) with each segment controlled by separate circuitry, allowing independent operation and simplifying the control architecture compared to a fully integrated system.
Solution Approach 2:
The light bar housing and mounting structure are designed to accommodate various LED configurations and colors (red, amber, white, clear) within a single universal platform, allowing the same basic structure to serve multiple lighting functions across different vehicle applications.
4Ease of operation
If light bar is designed for easy installation without drilling, then ease of installation is improved, but structural strength may be reduced
Solution Approach 1:
The patent employs adhesive mounting systems with high-strength bonding agents that provide sufficient mounting strength without requiring drilling or penetration of the vehicle body, enabling easy installation while maintaining adequate structural integrity.
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
The solution extends the light bar's lifespan, improves safety, and simplifies installation, offering a durable, aesthetically pleasing, and multi-functional lighting solution that fits various vehicles, with efficient heat dissipation and independent segment control.
Implementation Method 1
The circuit board includes a row of white, a row of amber, and a row of red LEDs
Implementation Method 2
The circuit board is fully encapsulated with an encapsulant within the housing
Implementation Method 3
installed using a plurality of adhesively attached clips
Data Source
AI summary
A light bar having an extruded housing with a curved cover portion and a flat back wall and flat side walls with a hollow interior. A circuit board positioned within the hollow interior and separated into a plurality of electrical segments. The circuit board includes a row of white, amber, and red LEDs which are fully encapsulated with an encapsulant within the housing. The ends of the housing are enclosed by end caps. The light bar is electrically connected to the electrical system of the vehicle and is installed using a plurality of adhesively attached clips and is controlled by a control box that interprets the operational signals of practically any commercially available pickup truck and outputs commands that controls illumination of the light bar. The compact size of the light bar facilitates installation of the light bar on practically any commercially available pickup truck.