Replaceable LED Strip Structure for Cargo Fitting Maintenance
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Solution Overview
Problem
LEDs in cargo compartments of commercial vehicles frequently fail due to thermal stress or mechanical damage, necessitating costly and maintenance-intensive replacement of the entire fitting.
Innovation Solution
A strip-shaped fitting with a groove-shaped receptacle and undercuts allows direct insertion and removal of an LED strip, using a dual-plastic material design where LEDs are embedded on a carrier, eliminating the need for additional fastening methods like gluing or screwing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LEDs are embedded in a plastic body and attached to fittings, then the cargo compartment is illuminated, but the LEDs frequently fail due to thermal stress or mechanical damage requiring replacement of the entire fitting
Solution Approach 1:
The LED strip is segmented into modular sections with individual electrical contacts, allowing replacement of only the defective LED module rather than the entire fitting. The plastic body is designed as a separate replaceable component from the metal fitting structure.
Solution Approach 2:
The plastic body provides thermal insulation and mechanical protection for the LEDs before failure occurs, cushioning them against thermal stress and mechanical damage. The bead design anticipates potential failure by enabling easy replacement without damage to the fitting.
2Reliability
If the entire fitting is replaced when LEDs fail, then functional reliability is restored, but maintenance costs and time increase
Solution Approach 1:
The system is divided into a permanent fitting structure and a replaceable LED strip module. Only the defective LED module needs to be removed and replaced, significantly reducing maintenance time and cost compared to replacing the entire fitting.
Solution Approach 2:
The LED strip is designed with pre-formed beads and electrical contacts that align with the fitting's groove and contacts, allowing for quick insertion and connection without complex assembly steps or additional fastening operations.
3Strength
If additional fastening methods like gluing or screwing are used, then the LED strip is more securely attached, but the replacement process becomes more complex and time-consuming
Solution Approach 1:
The attachment mechanism is segmented into the groove-shaped receptacle in the fitting and the corresponding beads on the LED strip. This mechanical interlocking provides secure attachment without requiring gluing or screwing, and allows for easy release when replacement is needed.
Solution Approach 2:
The beads act as intermediary elements that bridge the LED strip and the fitting's groove, providing both secure mechanical attachment and electrical contact alignment. This intermediary design simplifies both installation and replacement procedures.
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
Facilitates easy replacement or retrofitting of LED strips by allowing quick insertion and removal from existing fittings, reducing maintenance and costs.
Implementation Method 1
the plastic body is formed from a first and a second plastic material, wherein the first plastic material forms an outer body forming the outer side surfaces and the bottom surface of the plastic body, and the second plastic material forms an inner body filling the outer body and forming the top surface of the plastic body
Implementation Method 2
a plurality of LEDs arranged successively in a longitudinal axis of the strip-shaped plastic body and embedded in the plastic body
Data Source
Figure 1~2
Figure 3~4b
AI summary
LED strips (2) for strip-shaped fittings (1) for fastening in the cargo compartments of commercial vehicles, comprising a strip-shaped plastic body and a plurality of LEDs (3) arranged successively in a longitudinal axis (L) of the strip-shaped plastic body and embedded in the plastic body, wherein the plastic body has an upper top surface (8), two outer side surfaces (9a, 9b) spaced apart from each other in a first transverse axis (Q1) of the plastic body, and a lower bottom surface (10) spaced apart from the top surface (8) in a second transverse axis (Q2) of the plastic body.It is proposed that the outer side surfaces (9a, 9b) each transition into the lower bottom surface (10) via a bead (11a, 11b) extending the cross-section perpendicular to the longitudinal axis (L) parallel to the first transverse axis (Q1), and that the LEDs (3) are arranged on a strip-shaped carrier (12) embedded in the bead area of the plastic body enclosed by the two beaded sections (11a, 11b).