Auxiliary Light Non-Rectangular Housing Thermal Management
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Solution Overview
Problem
Existing auxiliary lighting systems for vehicles face challenges in providing adequate illumination without exceeding available space or power capacity, particularly in off-road and recreational applications.
Innovation Solution
A compact auxiliary light design featuring a non-rectangular housing with a circuit board and heat conductive pad, incorporating LED or laser light sources, and a transparent cover with varying optical properties for enhanced illumination, along with a mount and fins for improved airflow and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If additional light sources are added to achieve desired illumination, then illumination intensity is improved, but space requirements and power capacity are exceeded
Solution Approach 1:
The patent transitions from traditional bulb lighting to LED or laser light sources, fundamentally changing the illumination parameter. LEDs provide high illumination intensity with significantly reduced power consumption and heat generation, allowing adequate lighting within limited space and power capacity constraints
Solution Approach 2:
The patent replaces traditional mechanical bulb and reflector systems with solid-state LED or laser emitters that provide directional illumination inherently. This substitution eliminates the need for large reflectors and housing structures, reducing overall space requirements while maintaining or improving illumination intensity
2Illumination intensity
If additional light sources are added to achieve desired illumination, then illumination intensity is improved, but power capacity is exceeded
Solution Approach 1:
The patent changes the energy consumption parameter by adopting LED or laser light sources that consume significantly less power than traditional bulbs. LEDs can provide equivalent or superior illumination intensity while using 70-80% less electrical power, staying within vehicle power capacity limits
Solution Approach 2:
The patent implements directional illumination where the light source and its optics are optimized for specific beam patterns (spot, flood, or combination). This localized optimization of light distribution ensures efficient use of power by directing illumination precisely where needed rather than wasting energy in unnecessary directions
3Productivity
If LED or laser light sources are used to improve directional illumination, then illumination efficiency is improved, but heat management becomes more critical
Solution Approach 1:
The patent converts the harmful heat generated by LEDs into a manageable thermal flow by implementing dedicated heat sinks with thermal coupling to the LED substrates. The heat is conducted away from sensitive components and dissipated through optimized thermal pathways, turning a potential reliability issue into a controlled thermal management system
Solution Approach 2:
The patent introduces thermal interface materials and heat sink structures as intermediaries between the LED light sources and the external environment. These intermediaries facilitate efficient heat transfer from the small LED chips to larger heat dissipation surfaces, managing temperature while maintaining high illumination efficiency
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 efficient and directional illumination while optimizing space and power usage, ensuring effective visibility in various applications without extensive modifications to the vehicle.
Implementation Method 1
A heat conductive pad positioned between the circuit board and the back wall
Implementation Method 2
A light is mounted to the circuit board, the circuit board defining a circuit for driving the light. The light may be a light emitting diode (LED) or laser
Implementation Method 3
The light may be a light emitting diode (LED) or laser
Implementation Method 4
The transparent cover may have areas having different optical properties from one another. The different optical properties may include facet angle, tinting, focusing, and diffusing
Implementation Method 5
The different optical properties may include facet angle, tinting, focusing, and diffusing
Implementation Method 6
The different optical properties may include facet angle, tinting, focusing, and diffusing
Implementation Method 7
A plurality of fins may extend rearwardly from the back wall of the housing
Data Source
AI summary
An apparatus includes an auxiliary light includes a housing defining a front opening, a light emitting in the housing, and a transparent cover is mounted over the front opening. A plurality of fins are mounted to the housing and extend rearwardly from the front opening. The housing defines a cavity of non-rectangular shape from the opening to a backwall of the cavity. A circuit board has a perimeter conforming to the non-rectangular shape. The circuit board may include cutouts for a plug through the backwall. A heat conducting pad, such as graphite is interposed between the circuit board and the backwall and may likewise conform to the non-rectangular shape.