Cordless Light Housing Partitioning for Thermal Management

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Solution Overview

Problem

Existing cordless lights are not suitable for illuminating areas such as sheds, barns, and outdoor spaces, particularly in rainy and high humidity conditions, as they lack effective water resistance and efficient thermal management.

Innovation Solution

A cordless mountable light with a housing design that separates battery and light housings via a partitioning wall, incorporating a heat sink, air vents, and a removable 20V max power tool battery pack, which allows airflow for thermal management and includes a motion or darkness sensor for automatic activation, ensuring reliable operation in adverse conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If cordless lights are designed for portability and mounting in various locations, then ease of operation and versatility are improved, but water resistance and thermal management become problematic in outdoor and high-humidity environments

Engineering Contradiction:

Improvemounting versatilityVSAvoidwater resistance

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The housing is divided into a light housing and a battery housing separated by a partitioning wall. This segmentation allows each compartment to be optimized independently - the light housing can be sealed for water resistance while the battery housing accommodates thermal management requirements, resolving the contradiction between versatility and reliability in harsh environments.

Inventive Principle:

Principle #1Segmentation

2Illumination intensity

If LED modules are used to provide high light output, then illumination intensity is improved, but heat generation increases requiring effective thermal management

Engineering Contradiction:

Improvelight outputVSAvoidheat management

Core Design Contradiction:

Illumination intensityVSTemperature

Solution Approach 1:

The heat sink is extracted as a separate component within the light housing, positioned to receive airflow from the battery housing. This extraction of the thermal management function into a dedicated component allows the LED module to operate at high intensity while the heat sink independently manages the generated heat through passive convection cooling.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Airflow acts as an intermediary medium that transfers heat from the LED module through the heat sink to the external environment. The partitioning wall with intake opening creates a thermal pathway where ambient air serves as a heat transfer medium, enabling effective thermal management without direct thermal contact between the battery and light housing.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of operation

If battery packs are made removable for ease of replacement, then ease of operation is improved, but thermal isolation between battery and light housing becomes challenging

Engineering Contradiction:

Improvebattery replacementVSAvoidthermal management

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The removable battery pack design is combined with a partitioned housing structure. The partitioning wall creates thermal separation between the battery housing and light housing, allowing the battery to be easily removed and replaced while maintaining thermal isolation. This segmentation enables both ease of operation and effective thermal management simultaneously.

Inventive Principle:

Principle #1Segmentation

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 reliable and efficient lighting solution for sheds, barns, and outdoor spaces by ensuring effective thermal management and water resistance, with a light output of 1200 to 2000 lumens, suitable for various environments and conditions.

Implementation Method 1

an airflow passes in thermal contact with the battery pack from the battery housing into the light housing through the intake opening, and from the light housing in thermal contact with the heat sink out of the air vent

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

Methodology Applied

Scientific EffectForced convection: Forced Convection

Data Source

PatentUS11543093B2Light apparatus having air flow

Publication Date: 2023.01.03 BLACK & DECKER CORP

AI summary

A lighting apparatus is provided with a housing forming a battery housing and a light housing separated via a partitioning wall. A light module is supported by the light housing and includes a heat sink located at least partially within the light housing and at least one LED supported by the heat sink. A battery receptacle formed within the battery housing to slidingly receive a battery pack at least partially into the battery housing. An intake opening is formed within the partitioning wall and an air vent is formed in fluid communication with the light housing. In operation, an airflow passes in thermal contact with the battery pack from the battery housing into the light housing through the intake opening, and from the light housing in thermal contact with the heat sink out of the air vent.