Light Bar Housing with Embedded LED and Thermal Base
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Solution Overview
Problem
Conventional light bar structures utilizing surface mount technology have high manufacturing costs and complex production processes due to expensive materials like aluminum and copper, which also complicate the assembly of light emitting diodes.
Innovation Solution
A light bar structure with a housing that includes engaging and contacting portions to constrain light units, along with conductive components for electrode contact, and an isolating component made of resilient material to secure light units without surface mount technology, allowing for easy assembly and reduced material costs, while maintaining heat and optical efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If surface mount technology is used to fix light emitting diodes on aluminum or copper bases, then heat dissipating efficiency is improved, but manufacturing cost and production process complexity increase
Solution Approach 1:
The patent extracts the light emitting diode from the conventional SMT process and directly embeds it into the light guide plate. This eliminates the need for separate bases (aluminum or copper) and the complex SMT assembly process, while maintaining effective heat dissipation through direct thermal contact between the LED and the light guide plate.
Solution Approach 2:
The patent merges the base function with the light guide plate by directly embedding the LED into the light guide plate. This integration combines the heat dissipation function (previously performed by separate aluminum or copper bases) and the light guiding function into a single component, simplifying the overall structure and reducing manufacturing complexity.
2Temperature
If aluminum base is used for high power light emitting diode, then heat dissipating efficiency is improved, but material cost increases
Solution Approach 1:
The light guide plate is designed to perform multiple functions simultaneously: it guides light, dissipates heat, and provides structural support. By making the light guide plate multi-functional, the patent eliminates the need for separate expensive aluminum bases, thereby reducing material costs while maintaining effective heat dissipation.
Solution Approach 2:
The patent uses a cost-effective light guide plate material that can adequately perform heat dissipation functions without requiring expensive aluminum. The design accepts that the light guide plate may have a limited service life in high-power applications, but compensates by using more economical materials.
3Quantity of substance
If copper base is used for low power light emitting diode, then material cost is reduced, but heat dissipating efficiency deteriorates
Solution Approach 1:
The patent applies local quality enhancement by creating a specific embedding structure in the light guide plate where the LED is directly coupled. This localized design ensures optimal thermal contact between the LED and the light guide plate in the critical heat dissipation zone, while the rest of the light guide plate can use cost-effective materials.
4Ease of manufacture
If surface mount technology is used to fix light emitting diode, then assembly is achieved, but manufacturing cost and production process complexity increase
Solution Approach 1:
The patent employs preliminary action by pre-forming embedding cavities and thermal coupling structures within the light guide plate during its manufacturing process. This allows the LED to be directly embedded into the light guide plate without requiring separate mounting steps, thereby simplifying the assembly process while maintaining secure fixation and effective thermal contact.
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 cost-effective and simple assembly process for light bar structures that can be applied in both side-in and direct-type backlight modules without compromising heat dissipation or optical efficiency.
Implementation Method 1
the isolating component is made of resiliently deformable material
Implementation Method 2
the base is a metal structure processed by surface anodizing treatment
Implementation Method 3
the housing further includes a heat conductive portion disposed on a bottom of the accommodating space and connected to the base
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 housing includes an engaging portion for engaging with the light unit to constrain a movement of the light unit at a first direction, and a contacting portion for contacting against the light unit to constrain a movement of the light unit at a second direction different from the first direction. The light bar structure further includes an isolating component disposed on a bottom inside the housing, and two conductive components disposed on the isolating component for electrically connecting two electrodes of the light unit.