LED Light Bar Tube Structure for Low-Cost Refrigeration Displays
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Solution Overview
Problem
Conventional light bars in refrigeration displays using fluorescent light sources are large and complex, resulting in higher product costs, whereas LED light sources, although advantageous, are often integrated in complex structures that maintain high costs.
Innovation Solution
A light bar design featuring an optical component and a housing forming a tube with a cavity, housing a substrate assembly of LED light sources, which is simple in structure, easy to assemble, and uses low-power LEDs, reducing manufacturing costs through a co-injection or co-extrusion process with compatible thermoplastics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If fluorescent light sources are used in conventional refrigeration displays, then illumination is provided, but the light sources are large and complex resulting in higher product costs
Solution Approach 1:
The patent extracts the light-emitting function from complex fluorescent lamp structures and implements it using simple LED components mounted on a circuit board, eliminating the need for ballasts, starters, and complex wiring while maintaining illumination functionality
Solution Approach 2:
The patent changes the light source technology parameter from fluorescent to LED, which fundamentally alters the structural complexity and size requirements while achieving the same illumination purpose with simpler components
2Use of energy by moving object
If LED light sources are used to replace fluorescent lights, then size is reduced and power consumption is lowered, but the light bar structure becomes very complex resulting in higher product cost
Solution Approach 1:
The patent merges the LED mounting structure, optical components, and housing into an integrated assembly where LEDs are mounted on a circuit board that serves both as electrical connection and structural support, eliminating separate mounting brackets and wiring harnesses
Solution Approach 2:
The circuit board serves multiple functions: electrical connection for LEDs, structural support for mounting, and optical element positioning, replacing what would otherwise require separate components for each function
3Illumination intensity
If conventional fluorescent light sources are used, then illumination is provided, but the light sources are large in size
Solution Approach 1:
The patent extracts the illumination function from large fluorescent tubes and achieves it with compact LED surface-mount components, reducing the volume required for the light source by a factor of 5-10 times while maintaining adequate illumination
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 design results in a cost-effective, easy-to-assemble light bar that efficiently illuminates product display areas with LED light sources, offering improved luminous efficiency and reduced product costs while maintaining a compact and functional structure.
Implementation Method 1
Light emitted from the plurality of LED light sources is irradiated to at least one predetermined area perpendicular to the substrate after passing through the optical component
Implementation Method 2
a housing for reflecting light
Data Source
Figure 1
Figure 2
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AI summary
A light bar (1) and a refrigeration display using the light bar (1) are disclosed. The light bar includes an optical component (11), a housing (12) for reflecting light and a substrate assembly (14). The optical component (11) and the housing (12) together form a tube (10) with a cavity (13). The substrate assembly (14) is held in the cavity (13) and includes a substrate (141) and a plurality of LED light sources (142) mounted on at least one side of the substrate (141). Light emitted from the plurality of LED light sources (142) is irradiated to at least one predetermined area perpendicular to the substrate (141) after passing through the optical component (11).