LED projection lamp device based on TIR lens
By using TIR lenses and an active cooling system, the heat dissipation and sealing problems of LED floodlights in outdoor environments are solved, achieving efficient dual lighting effects and reliability, and meeting the lighting needs of large areas and long distances.
Patent Information
- Application Number
- CN202512053112.4
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-31
- Publication Date
- 2026-02-10
AI Technical Summary
Existing LED floodlights have poor heat dissipation performance in harsh outdoor environments. Their sealed structure makes it difficult for heat to escape, affecting the lifespan of the lights and making them susceptible to corrosion from moisture. They cannot simultaneously meet the needs of large-area lighting and long-distance projection.
It adopts a TIR lens design, combined with a heat spreader, heat pipes and heat dissipation fins, to achieve active heat dissipation by utilizing the chimney effect and thermal buoyancy flow channels, and maintains airtightness through a labyrinth waterproof partition and ePTFE membrane. It integrates main floodlight and high-brightness spotlight modules to meet dual lighting needs.
It effectively solves the problem of heat buildup in LED floodlights, improves outdoor reliability and lighting effect, and ensures that the luminaires maintain good heat dissipation and waterproof performance under high protection levels.
Smart Images
Figure CN121498031A_ABST
Abstract
Description
Technical Field
[0001] This invention belongs to the field of lighting device technology, specifically an LED floodlight device based on a TIR lens. Background Technology
[0002] With the rapid development of LED technology, high-power LED floodlights, due to their high brightness, low energy consumption, and long lifespan, are widely used in outdoor scenarios such as architectural lighting, industrial and mining operations, tunnel lighting, and large plazas. Because these lighting devices typically need to operate for extended periods in harsh outdoor environments, high reliability is required of the luminaires.
[0003] To meet the needs of long-distance projection or large-area lighting, existing LED floodlights on the market have extremely high LED module power density. When the lamp works for a long time, the core junction temperature rises rapidly. If the heat cannot be dissipated in time, it will lead to accelerated LED light decay and color temperature drift, which will seriously shorten the lamp's lifespan. In addition, to cope with outdoor rain, dust and humid environments, floodlights usually adopt a fully enclosed structure (the protection level is usually required to reach IP65 or even IP67). The tight sealing structure blocks the natural convection of internal and external air, making it impossible for internal hot air to escape. Existing LED floodlights mostly rely on heat dissipation fins on the surface of the shell for passive heat dissipation. However, in still, windless environments or high-temperature summer environments, it is difficult to cope with the huge amount of heat generated by high-power modules by relying solely on the heat radiation of the shell and weak natural convection. Moreover, the thermal expansion and contraction effect of air in the enclosed cavity (breathing effect) can easily cause slight deformation of the shell or failure of the sealing ring, which in turn leads to the intake of moisture and corrosion of the internal circuitry. Summary of the Invention
[0004] To overcome the shortcomings of existing technologies and solve problems such as limited heat dissipation fin area of high-power outdoor lighting fixtures, unreasonable design of natural convection paths, and difficulty in dissipating internal heat due to high-protection-level sealed structures, this invention proposes an LED floodlight device based on a TIR lens.
[0005] The technical solution adopted by this invention to solve its technical problem is: an LED floodlight device based on a TIR lens, comprising: Mounting base, convection heat exchange components and wide-angle floodlight module; The main light source substrate is fixed to the rear side of the mounting base, and the main floodlight LED light source is mounted on the main light source substrate; The convection heat exchange component is disposed on the top of the mounting base and forms a thermal conduction connection with the main light source substrate. The convection heat exchange component includes a rear sealing cover plate that defines the back space and a heat sink located on the top. The heat sink has an air inlet and a built-in heat exchange tube bundle to form an airflow channel that guides hot air to flow upward and exchange heat. The wide-angle floodlight module is located on the front side of the mounting base and includes a focusing light source substrate and a high-brightness focusing LED unit; as well as a composite optical lens group, including a wide-angle diffuser TIR lens that works with the main floodlight LED light source and a narrow-angle focusing TIR lens that works with the high-brightness focusing LED unit.
[0006] Preferably, a reflector is fixedly connected to the top of the main light source substrate, and four thermal buoyancy guiding channels are equidistantly opened on the reflector, which are configured to guide airflow into the heat sink by utilizing the principle of hot air rising.
[0007] Preferably, a heat spreader is fixedly connected to the bottom of the main light source substrate, a thermally conductive pad is provided between the main light source substrate and the heat spreader, and multiple heat dissipation fin groups are fixedly connected at equal intervals to the bottom of the heat spreader, with two heat-conducting heat pipes fixedly connected through the multiple heat dissipation fin groups.
[0008] Preferably, the heat sink has multiple through holes, and each pair of heat sink cavities is connected through the through holes. Each heat sink cavity is fixedly connected with a heat exchange tube bundle, and both ends of each heat exchange tube bundle are connected to the through holes.
[0009] Preferably, a guide plate is fixedly connected to the side of the heat sink near the air inlet, and multiple turbulence-conducting baffles are fixedly connected at equal intervals inside the heat sink, with the multiple turbulence-conducting baffles arranged in a crisscross pattern.
[0010] Preferably, the rear sealing cover has three vents at equal intervals, all three vents are connected to the interior of the heat sink, and three labyrinth-type waterproof partitions are fixedly connected inside each of the three vents. The labyrinth-type waterproof partitions are arranged in groups of three, and the labyrinth-type waterproof partitions in each group are staggered vertically.
[0011] Preferably, the mounting base has four internal cavity pressure balance holes equidistantly arranged on it. An air intake grille frame is fixedly connected to the side of the mounting base away from the main light source substrate. Four ambient air inlets are equidistantly arranged on the air intake grille frame. All four ambient air inlets are connected to the internal cavity pressure balance holes. An ePTFE membrane is fixedly connected to each of the four ambient air inlets. A breathable membrane support mesh is fixedly connected to the inner wall of each of the four ambient air inlets on the side of the ePTFE membrane closest to the mounting base.
[0012] Preferably, each of the four ambient air inlets is fixedly connected to an air inlet dust cover on the side away from the mounting base.
[0013] Preferably, a narrow-angle focusing TIR lens is fixedly connected to the side of the mounting base away from the main light source substrate, and three collimating focusing lens units are fixedly connected at equal intervals inside the narrow-angle focusing TIR lens.
[0014] Preferably, an anti-glare awning is fixedly connected to the side of the mounting base away from the main light source substrate, and the anti-glare awning is located directly above the wide-angle diffusion TIR lens.
[0015] The beneficial effects of this invention are as follows: 1. The present invention discloses an LED floodlight device based on a TIR lens. This device achieves rapid heat conduction at the bottom through the synergistic effect of a heat spreader, heat pipes, and heat dissipation fins. Utilizing the chimney effect, hot air is introduced into the heat exchange chamber at the top through a thermal buoyancy guide channel. The hot air is repeatedly folded back in the S-shaped flow channel formed by the turbulent heat-conducting baffles and undergoes efficient heat exchange with the built-in heat exchange tube bundle, thus solving the problem of heat accumulation in high-power floodlights under calm wind conditions.
[0016] 2. The LED floodlight device based on TIR lens described in this invention integrates a main floodlight and a high-brightness spotlight dual module. Utilizing TIR lens technology, the wide-angle diffuser TIR lens provides a wide range of basic ambient lighting (floodlight), while the narrow-angle spotlight TIR lens provides long-distance focused supplementary lighting (spotlight) through a collimated optical path. This allows it to simultaneously meet the dual requirements of a wider lighting range and a longer lighting distance in scenarios such as squares and construction sites.
[0017] 3. The LED floodlight device based on a TIR lens described in this invention integrates an ePTFE waterproof and breathable membrane at the ambient air inlet. Its microporous structure allows gas molecules to pass freely to balance the air pressure difference inside and outside the lamp, completely eliminating the risk of water absorption due to the breathing effect caused by thermal expansion and contraction. The exhaust port adopts a labyrinth-style waterproof baffle design to effectively prevent rainwater backflow. While ensuring a high protection level of IP65 or above, it retains the gas exchange channel, improving the reliability of the lamp in outdoor humid and hot environments. Attached Figure Description
[0018] The invention will now be further described with reference to the accompanying drawings.
[0019] Figure 1 This is a three-dimensional schematic diagram of the overall structure of the present invention; Figure 2 This is a three-dimensional schematic diagram of the main light source substrate and its upper and lower side structures of the present invention; Figure 3 This is a schematic diagram of the reflector and thermal buoyancy guiding channel structure of the present invention; Figure 4 This is a three-dimensional schematic diagram of the connection structure between the rear sealing cover and the heat sink of the present invention; Figure 5 This is a cross-sectional schematic diagram of the heat sink and its internal structure of the present invention; Figure 6 This is the invention Figure 5 Enlarged view of point A in the middle; Figure 7 This is a cross-sectional schematic diagram of the exhaust port and baffle structure of the present invention; Figure 8 This is a three-dimensional schematic diagram of the environmental air intake and its internal structure of the present invention; Figure 9 This is a cross-sectional schematic diagram of the ePTFE membrane and the breathable membrane support mesh structure of the present invention; Figure 10 This is a schematic diagram of the structure of the heat sink and guide plate of the present invention; Figure 11 This is a cross-sectional schematic diagram of the heat dissipation cavity and through hole connection structure of the present invention; Figure 12 This is a three-dimensional schematic diagram of the light-concentrating light source substrate and the high-brightness light-concentrating LED unit structure of the present invention; Figure 13 This is a schematic diagram of the narrow-angle focusing TIR lens and collimating focusing lens unit of the present invention; Figure 14 This is a schematic diagram of the light emitted by the main floodlight LED light source of the present invention during operation.
[0020] In the picture: 100. Mounting base; 101. Inner cavity pressure balance hole; 110. Main light source substrate; 111. Main floodlight LED light source; 120. Reflector; 121. Thermal buoyancy guide channel; 130. Heat spreader plate; 131. Thermal pad; 140. Heat dissipation fin assembly; 141. Thermal pipe; 200. Convection heat exchange assembly; 210. Rear sealing cover; 220. Heat sink; 221. Air inlet; 222. Heat dissipation cavity; 223. Through hole; 224. Heat exchange tube bundle; 230. Guide plate; 240. Baffle one; 250. Exhaust port; 251. Baffle two; 260. Air inlet grille frame; 270. Ambient air inlet; 271. ePTFE membrane; 272. Breathable membrane support mesh; 280. Air inlet dust cover; 300. Wide-angle floodlight module; 310. Focusing light source substrate; 311. High-brightness focusing LED unit; 320. Narrow-angle focusing TIR lens; 321. Collimating focusing lens unit; 330. Wide-angle diffuser TIR lens; 340. Anti-glare glare. Detailed Implementation
[0021] To make the technical means, creative features, objectives and effects of this invention easier to understand, the invention will be further described below in conjunction with specific embodiments.
[0022] like Figure 1 As shown, this embodiment discloses an LED floodlight device based on a TIR lens.
[0023] like Figure 1 As shown, the device mainly consists of a mounting base 100 supporting the main body, a convection heat exchange component 200 located at the top, and a wide-angle floodlight module 300 located at the front. The mounting base 100, the convection heat exchange component 200, and the wide-angle floodlight module 300 are housed inside the lamp housing (not shown in the figure). Figure 3 As shown, in the core light source arrangement, a main light source substrate 110 is fixed to the rear wall of the mounting base 100 by screws or thermally conductive adhesive. A high-power main floodlight LED light source 111 high-power patch array is mounted on this substrate to provide large-area basic floodlight illumination, such as... Figure 4 As shown, to solve the heat dissipation problem of high-power light sources, a convection heat exchange component 200 is specifically disposed in the top region of the mounting base 100 and maintains a tight thermal conduction connection with the main light source substrate 110. This component consists of a rear sealing cover 210 on the rear side and a heat sink 220 on top, i.e., a heat exchange gas collection chamber, which together define a back space for gas heat exchange. The heat sink 220 is not a solid structure, as shown... Figure 5 and Figure 6 As shown, an air inlet 221 is provided on the side away from the rear sealing cover 210, and a heat exchange tube bundle 224 is integrated inside. This structural design creates a vertical airflow channel inside the lamp, utilizing the physical property of hot air rising to actively guide the heat accumulated near the light source to the top for exchange, such as... Figure 12 As shown, in terms of optical output, the device adopts a composite optical path design. Besides the aforementioned main floodlight LED light source 111, it also incorporates a wide-angle diffuser TIR lens 330 at the bottom to form a... Figure 14 In addition to the wide beam pattern shown, the device also integrates a wide-angle floodlight module 300 on the front side. This module includes an independent focusing light source substrate 310 and a high-brightness focusing LED unit 311, and works with a narrow-angle focusing TIR lens 320 to project a center beam over a long distance, thereby achieving a composite lighting effect of wide paving and long focusing.
[0024] like Figure 2As shown, a reflector 120 is fixedly connected to the top of the main light source substrate 110. The reflector 120 not only serves to converge light, but also incorporates fluid dynamics principles. Four thermal buoyancy guiding channels 121 are equidistantly opened on the wall of the reflector 120. When the lamp is working, the air in the sealed cavity is heated and expands, reducing its density. Driven by the chimney effect, when the rising hot air fully contacts and exchanges heat with the heat exchange tube bundle 224 and the turbulence-conducting heat baffle 240 inside the heat sink 220, the air temperature decreases, causing the density to increase. The cooled airflow, under the influence of gravity, naturally sinks along the low-temperature zones on both sides of the inner wall of the heat sink 220 and the mounting base 100. Since there is a backflow gap between the main light source substrate 110 and the inner wall of the mounting base 100, the cooling airflow can flow smoothly back to the bottom space of the device and re-contact the heating zone composed of the heat spreader 130 and the heat dissipation fin assembly 140. The airflow forms a self-sustaining convection circulation that rises in the middle and sinks around the perimeter in the sealed cavity, achieving the transfer of internal heat to the top without compromising the IP65 protection level.
[0025] like Figure 2 and Figure 3 As shown, a large-area heat spreader 130, typically made of copper or aluminum alloy, is fixedly connected to the bottom of the main light source substrate 110. A thermally conductive pad 131 made of graphene or phase change material is sandwiched between the two to eliminate contact thermal resistance. The bottom of the heat spreader 130 extends downward and is connected to multiple heat dissipation fin groups 140 at equal intervals. Two or more heat pipes 141 are fixed through the multiple heat dissipation fin groups 140. The heat pipes utilize the phase change cycle of the working fluid inside to quickly distribute the high heat in the center of the main light source substrate 110 to the far end of the entire heat dissipation fin group 140, thereby improving the overall utilization rate of the bottom heat dissipation module and ensuring that heat can be quickly transferred to the cold air passing through the bottom.
[0026] like Figure 6 and Figure 11 As shown, the main body of the heat sink 220 has multiple through holes 223 for airflow passage. Each pair of adjacent heat sink 222 is connected through these through holes 223. In each heat sink 222, a heat exchange tube bundle 224, usually made of aluminum or copper, is fixed horizontally or vertically. The two ends of the tube bundle are connected to the through holes 223. This design allows the cooler external air to pass through the inside of the tube bundle, while the hot air rising inside flows through the outside of the tube bundle, thereby increasing the contact area between the hot and cold airflows without mixing them, thus ensuring the airtightness of the lamp.
[0027] like Figure 6 and Figure 10As shown, a guide plate 230 is provided on the side of the heat sink 220 near the air inlet 221 to initially regulate the rising airflow. Multiple turbulence-inducing heat-conducting baffles 240 are fixed at equal intervals along the airflow direction inside the heat sink 220. These baffles are arranged in a crisscrossing manner or an alternating manner. The crisscrossing baffles force the hot air to form an S-shaped or serpentine flow path in the heat dissipation cavity 222. During the tortuous process, the airflow is forced to repeatedly scour the outer wall of the heat exchange tube bundle 224 and the inner wall of the heat dissipation cavity, which enhances the degree of turbulence and the heat transfer coefficient, thereby achieving a large heat exchange efficiency in a limited space.
[0028] like Figure 5 and Figure 7 As shown, the rear sealing cover 210 has three exhaust ports 250, which are connected to the heat sink 220. In order to prevent outdoor rainwater from flowing back through the exhaust ports, each exhaust port 250 is equipped with a set of three labyrinth-style waterproof baffles 251. These baffles are arranged in an alternating pattern to form an S-shaped labyrinth channel. Gas molecules can smoothly bypass the baffles and be discharged, but liquid water droplets or rainwater with mass and inertia cannot pass through the labyrinth due to gravity and the obstruction of the baffles, thus achieving physical waterproofing.
[0029] like Figure 8 and Figure 9 As shown, the mounting base 100 has four internal pressure balance holes 101. An air intake grille frame 260 is installed on the outside of the base, and an ambient air intake 270 corresponding to the internal pressure balance holes is provided on it. In terms of core protection, each ambient air intake 270 integrates an ePTFE membrane 271 expanded polytetrafluoroethylene membrane, and a breathable membrane support net 272 is fixed near its inner side. Outdoor lamps will generate huge internal pressure fluctuations and breathing effects when there are temperature differences between day and night or when the lights are switched on and off. The ePTFE membrane has a microporous structure, which allows air molecules to pass freely to balance the pressure, completely eliminating the risk of water ingress due to seal failure caused by negative pressure air intake. Moreover, its micropores are extremely small and can effectively block liquid water and dust from entering. The side of each of the four ambient air intakes 270 away from the mounting base 100 is fitted with an air intake dust cover 280 to block large particles of mud, sand, leaves or insects, prevent them from clogging the ePTFE membrane or air intake grille, and reduce the maintenance frequency.
[0030] like Figure 12 and Figure 13 As shown, the narrow-angle focusing TIR lens 320 integrates three independent collimating focusing lens units 321, which correspond to the high-brightness focusing LED unit 311 below. Each collimating unit collects and collimates the light emitted by one LED by total internal reflection, compressing the divergence angle to a very small range (such as 5°-15°), thereby forming a high-brightness central light spot at a distance.
[0031] like Figure 12 and Figure 13As shown, an anti-glare awning 340 is fixed to the front top of the mounting base 100. Its position is precisely above the wide-angle diffuser TIR lens 330. The anti-glare awning physically cuts off the upward overflow of invalid light, establishes a clear cutoff line between light and dark, and ensures that the light is mainly projected onto the target area such as the ground or wall, thereby improving the comfort and compliance of the lighting.
[0032] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the present invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.
Claims
1. An LED floodlight device based on a TIR lens, characterized in that, Including: Mounting base (100), convection heat exchange assembly (200) and wide-angle floodlight module (300); The main light source substrate (110) is fixed to the rear side of the mounting base (100), and the main floodlight LED light source (111) is mounted on the main light source substrate (110). The convection heat exchange assembly (200) is disposed on the top of the mounting base (100) and forms a thermal conduction connection with the main light source substrate (110). The convection heat exchange assembly (200) includes a rear sealing cover (210) defining the back space and a heat sink (220) located on the top. The heat sink (220) has an air inlet (221) and a heat exchange tube bundle (224) built in to form an airflow channel that guides hot air to flow upward and perform heat exchange. The wide-angle floodlight module (300) is located on the front side of the mounting base (100) and includes a focusing light source substrate (310) and a high-brightness focusing LED unit (311); as well as a composite optical lens group, including a wide-angle diffuser TIR lens (330) that works with the main floodlight LED source (111) and a narrow-angle focusing TIR lens (320) that works with the high-brightness focusing LED unit (311).
2. The LED floodlight device based on a TIR lens according to claim 1, characterized in that, A reflector (120) is fixedly connected to the top of the main light source substrate (110). Four thermal buoyancy guide channels (121) are equidistantly provided on the reflector (120), which are configured to guide airflow into the heat sink (220) by utilizing the principle of hot air rising.
3. The LED floodlight device based on a TIR lens according to claim 2, characterized in that, A heat spreader plate (130) is fixedly connected to the bottom of the main light source substrate (110). A heat-conducting pad (131) is provided between the main light source substrate (110) and the heat spreader plate (130). Multiple heat dissipation fin groups (140) are fixedly connected at equal intervals to the bottom of the heat spreader plate (130). Two heat-conducting heat pipes (141) are fixedly connected through the multiple heat dissipation fin groups (140).
4. The LED floodlight device based on a TIR lens according to claim 3, characterized in that, The heat sink (220) has multiple through holes (223), and each pair of heat sink cavities (222) are connected through the through holes (223). Each heat sink cavity (222) is fixedly connected with a heat exchange tube bundle (224), and both ends of each heat exchange tube bundle (224) are connected to the through holes (223).
5. The LED floodlight device based on a TIR lens according to claim 4, characterized in that, A guide plate (230) is fixedly connected to the side of the heat sink (220) near the air inlet (221). Multiple turbulence-conducting baffles (240) are fixedly connected at equal intervals inside the heat sink (220), and the multiple turbulence-conducting baffles (240) are arranged in a crisscross pattern.
6. The LED floodlight device based on a TIR lens according to claim 1, characterized in that, The rear sealing cover (210) has three vents (250) at equal intervals. All three vents (250) are connected to the interior of the heat sink (220). Each of the three vents (250) is fixedly connected to three labyrinth waterproof partitions (251). The labyrinth waterproof partitions (251) are arranged in groups of three, and the labyrinth waterproof partitions (251) in each group are staggered vertically.
7. The LED floodlight device based on a TIR lens according to claim 1, characterized in that, The mounting base (100) has four internal cavity pressure balance holes (101) equidistantly arranged on it. An air intake grille frame (260) is fixedly connected to the side of the mounting base (100) away from the main light source substrate (110). Four ambient air inlets (270) are equidistantly arranged on the air intake grille frame (260). All four ambient air inlets (270) are connected to the internal cavity pressure balance holes (101). An ePTFE membrane (271) is fixedly connected inside each of the four ambient air inlets (270). A breathable membrane support net (272) is fixedly connected to the inner wall of each of the four ambient air inlets (270) on the side of the ePTFE membrane (271) close to the mounting base (100).
8. The LED floodlight device based on a TIR lens according to claim 7, characterized in that, Each of the four ambient air inlets (270) is fixedly connected to an air inlet dust cover (280) on the side away from the mounting base (100).
9. The LED floodlight device based on a TIR lens according to claim 1, characterized in that, The narrow-angle focusing TIR lens (320) has three collimating focusing lens units (321) fixedly connected at equal intervals.
10. The LED floodlight device based on a TIR lens according to claim 1, characterized in that, An anti-glare awning (340) is fixedly connected to the side of the mounting base (100) away from the main light source substrate (110), and the anti-glare awning (340) is located directly above the wide-angle diffusion TIR lens (330).