Light Bar Structure Using Buckling Components for LED Fixation
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Solution Overview
Problem
Conventional light bar structures utilizing surface mount technology (SMT) are expensive and have complex manufacturing processes due to the high cost of materials like aluminum and copper, and the need for precise assembly of light emitting diodes (LEDs).
Innovation Solution
A light bar structure with a housing and L-shaped buckling components that securely hold light units without SMT, using conductive materials for electrical connection and resilient materials for secure fixation, allowing for easy assembly and low material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If surface mount technology is used to fix LEDs on aluminum or copper bases, then heat dissipating efficiency and LED fixation reliability are improved, but manufacturing cost and production process complexity increase significantly
Solution Approach 1:
The patent replaces the complex surface mount technology (SMT) mechanical system with a simple buckling component mechanism. The buckling component uses elastic deformation to clamp and fix the LED, eliminating the need for SMT equipment and complex assembly processes while maintaining reliable LED fixation.
Solution Approach 2:
The buckling component is designed to automatically clamp and fix the LED through its elastic deformation characteristics. The component self-adjusts to secure the LED in place without requiring complex external fixation mechanisms or multi-step assembly processes, thereby simplifying the production process while ensuring reliable LED positioning.
2Temperature
If aluminum material is used for the base, then heat dissipating efficiency is improved, but material cost increases
Solution Approach 1:
The patent changes the material parameter of the base from expensive aluminum to cost-effective plastic material. The buckling component made of plastic with appropriate elastic properties achieves both cost reduction and functional requirements, while heat dissipation is managed through the overall structure design rather than relying solely on high-conductivity base material.
Solution Approach 2:
The patent employs a composite structure where the plastic base is combined with conductive materials or heat dissipation features in the buckling component design. This composite approach allows the use of cheaper plastic material while maintaining adequate heat dissipation performance through strategic integration of thermal management features.
3Quantity of substance
If copper base (FR4 plate) is used instead of aluminum base, then material cost is reduced, but heat dissipating efficiency decreases
Solution Approach 1:
The patent changes the base material from copper/FR4 composite to plastic material with modified structural parameters. The buckling component's elastic properties and structural design compensate for the lower thermal conductivity of plastic, maintaining adequate heat dissipation while achieving cost reduction.
4Reliability
If conventional SMT process is used for assembly, then LED fixation reliability is improved, but manufacturing cost and assembly time increase
Solution Approach 1:
The patent segments the LED fixation function from the complex SMT process into a simple buckling component mechanism. This segmentation allows the LED to be fixed independently using the elastic clamping action of the buckling component, eliminating the need for soldering and complex alignment procedures, thereby significantly improving assembly speed while maintaining fixation reliability.
Solution Approach 2:
The patent replaces the SMT mechanical system with a simple elastic buckling mechanism. The buckling component uses material elasticity to provide secure LED fixation without requiring soldering equipment, complex alignment fixtures, or multi-step assembly processes, thereby dramatically improving assembly speed and productivity.
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 enables a simple, cost-effective assembly method that maintains heat dissipating and optical efficiency, suitable for both side-in and direct-type backlight modules, with reduced manufacturing costs and no compromise on LED performance.
Implementation Method 1
a slot is formed on the first base, a plurality of sections on the first base is separated by the slot, and each section is for supporting the corresponding light unit
Data Source
AI summary
A light bar structure is disclosed in the present invention. The light bar structure includes a housing whereinside an accommodating space is formed, and the accommodating space is for accommodating a light unit. The light bar structure further includes a first buckling component disposed on an inner side of the accommodating space. The buckling component includes a first base disposed on a bottom inside the housing for supporting the light unit, a first arm connected to the first base and disposed on a first lateral wall inside the housing, and a first constraining portion disposed on the first arm for contacting against the light unit, so as to constrain a movement of the light unit relative to the first base.