Air Deflectors for Heat Management in Lighting Modules

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Solution Overview

Problem

Solid-state light emitters, such as LEDs, generate high temperatures that can cause overheating and damage during use, leading to downtime and reduced efficiency in curing processes due to inadequate heat management, which also disrupts the curing process by expelling air onto the medium.

Innovation Solution

The implementation of air deflectors that guide heat and air away from the housing in a direction opposite to the curing medium, using a combination of heat sinks and deflectors to manage heat expulsion without disturbing the curing process, with deflectors being secured to the housing using tabs and screws to ensure effective air guidance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If heat sinks are used to remove heat from the housing, then heat management is improved, but air is expelled onto the curing medium causing disturbance and damage

Engineering Contradiction:

Improveheat managementVSAvoidair disturbance to curing medium

Core Design Contradiction:

TemperatureVSObject-affected harmful factors

Solution Approach 1:

A deflector is introduced as an intermediary component between the heat sink and the curing medium. The deflector intercepts the hot air flow generated by the heat sink and redirects it away from the curing medium, thereby mediating the harmful interaction between cooling airflow and the curing process.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The housing is segmented into distinct functional zones: a curing zone where the medium is processed, and a cooling zone where heat sinks operate. The deflector acts as a partition between these zones, allowing both cooling and curing to occur simultaneously without interference.

Inventive Principle:

Principle #1Segmentation

2Reliability

If solid-state light emitters are used for curing, then power consumption is reduced and reliability is improved, but high temperatures cause overheating and component damage

Engineering Contradiction:

Improveemitter reliabilityVSAvoidoverheating risk

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The high temperature output of solid-state light emitters, which initially causes overheating, is converted into a benefit by using heat sinks to capture and redirect this thermal energy. The same thermal energy that threatens component damage is harnessed for controlled heat management, preventing overheating while maintaining emitter reliability.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The thermal parameters of the system are actively managed by introducing heat sinks that change the temperature distribution. The heat sinks absorb excess heat from the emitters and transfer it to the airflow, which is then redirected by deflectors to prevent localized overheating while maintaining overall system reliability.

Inventive Principle:

Principle #35Parameter changes

3Temperature

If cooling systems are added to manage heat, then temperature control is improved, but device complexity increases

Engineering Contradiction:

Improvetemperature controlVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The cooling system is designed to be self-regulating, using the natural convection currents generated by the heat sinks themselves. The hot air rises naturally and is redirected by the deflectors without requiring additional fans or active control mechanisms, allowing the system to self-manage temperature control while minimizing added complexity.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The cooling function is merged with the existing housing structure. Heat sinks are integrated into the housing design, and deflectors are positioned to utilize the same airflow paths already present in the curing chamber, combining multiple functions into a unified system rather than adding separate complex cooling subsystems.

Inventive Principle:

Principle #5Merging (Combining)

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

This solution effectively reduces overheating and minimizes disruption to the curing process by directing heat and air away from the medium, thereby increasing the reliability and efficiency of solid-state light emitters and reducing manufacturing costs.

Implementation Method 1

these cooling systems include one or more heat sinks that help remove heat generated by the solid-state light emitters from the housing through openings or other heat exits in the housing, which results in air being expelled from the housing

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS9170013B2Air deflectors for heat management in a lighting module

Publication Date: 2015.10.27 EXCELITAS TECHNOLOGIES CORP

AI summary

A lighting module has an array of light-emitting elements that is electrically coupled to a heat sink and a housing having a heat exit. The array of light-emitting elements is positioned in the housing and the heat sink is positioned to dissipate heat generated within the housing so that the heat is expelled through the heat exit. A deflector is secured to the housing and is positioned to extend over some portion of the heat exit. The deflector guides heat away from the housing in a direction. In some configurations, the deflector guides heat away from the housing in a direction that is opposite the direction in which the array of light-emitting elements emit light. Also, some lighting modules have multiple heat exits and may have multiple deflectors extending over a portion of the respective heat exits.