Angled LED Lighting Units for Light Box Illumination
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Solution Overview
Problem
Conventional lighting units for light boxes and sign cabinets face issues with short lifespan and low electrical efficiency, particularly with incandescent and fluorescent bulbs, and lack flexibility in adjusting LED density for optimal illumination.
Innovation Solution
A lighting system comprising a light box housing with interconnected LED units on angled PCBs and optical elements to alter light distribution, allowing for customizable and efficient illumination with adjustable LED density and improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional light sources (incandescent bulbs, neon bulbs, fluorescent tubes) are used in light boxes, then sufficient lighting can be provided, but the lifespan is short and electrical efficiency is low
Solution Approach 1:
The patent changes the fundamental parameters of the light source by transitioning from incandescent/neon/fluorescent technologies to LED technology. This parameter change results in dramatically improved electrical efficiency (converting most energy to light rather than heat) and extended operational lifespan (50,000-70,000 hours versus 750-20,000 hours for conventional sources), directly resolving the technical contradiction between energy efficiency and reliability
Solution Approach 2:
The patent replaces conventional mechanical/electrical light generation systems (incandescent filaments, neon gas discharge, fluorescent phosphor excitation) with solid-state LED technology. This substitution eliminates the mechanical wear and thermal degradation issues inherent in conventional sources, providing both superior energy efficiency and extended lifespan without requiring complex support systems
2Reliability
If LEDs are used to improve energy efficiency and lifespan, then electrical efficiency and lifespan are improved, but the light distribution pattern may not be optimal for illuminating the entire light box surface evenly
Solution Approach 1:
The patent employs asymmetric PCB mounting angles (e.g., 45-degree angles) for the LED units rather than symmetric perpendicular mounting. This asymmetric configuration allows the light distribution pattern to be optimized for even coverage across the light box surface, compensating for the directional nature of LED emission and eliminating hot spots or dark areas that would result from symmetric mounting
Solution Approach 2:
The patent introduces angular orientation as an additional dimension of control for light distribution. By mounting PCBs at specific angles rather than only perpendicular to the light box surface, the system achieves uniform illumination across the entire surface area, transforming the light distribution from a single-dimension vertical pattern to a multi-dimensional coverage pattern that eliminates shadows and hot spots
3Illumination intensity
If LED density is increased to improve illumination, then light output is improved, but heat dissipation becomes more difficult and device complexity increases
Solution Approach 1:
The patent divides the LED lighting system into multiple discrete, modular units distributed across the light box interior rather than using a single high-density array. Each unit contains a manageable number of LEDs on individual PCBs mounted at angles, which segments the heat generation into multiple small sources that are easier to dissipate individually, preventing heat buildup that would occur with high-density concentrated mounting
Solution Approach 2:
The patent utilizes angular mounting of PCBs to distribute LED units in three-dimensional space rather than confining them to a single flat plane. This spatial distribution in multiple dimensions increases the effective surface area for heat dissipation and improves airflow patterns around the LED units, enabling higher overall light output without corresponding increases in localized temperature
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 provides a cost-effective, reliable, and flexible lighting system with extended lifespan and improved energy efficiency, enabling even light dispersion and reduced profile, suitable for various applications including structural, display, and ingress/egress lighting.
Implementation Method 1
at least one light emitting element mounted on the at least one PCB, the at least one light emitting element being configured to be disposed on at least one angled surface and to emit light in a direction relative to the at least one angled surface
Implementation Method 2
at least one optical element proximate the at least one light emitting element and arranged to alter the light emitted from the at least one light emitting element to produce a desired light distribution pattern
Data Source
Figure 1~2a
Figure 2b~3
Figure 4a~4c
AI summary
A lighting system comprising a light box housing, a plurality of lighting units including a housing, a plurality of light emitting elements mounted on a PCB within the housing. The light emitting elements arranged on an angled surface such that the light emitting elements emit light in a sideways direction from the lighting units. The lighting units can also be interconnected in a daisy-chain configuration, such that the lighting units form a row of lighting units. The row of lighting units adapted to be mounted within the light box housing, wherein the light box housing comprises one or more rows of lighting units.