Dual-Horn Light Collimating Assembly Thermal Management
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Solution Overview
Problem
Concentrating LEDs in a small area for directional light control poses challenges in thermal management, as heat dissipation becomes difficult, requiring complex cooling solutions that complicate light directionality.
Innovation Solution
A dual-horn light collimating assembly with a larger outer horn and a partially contained inner horn, allowing for controlled light collimation and integrated thermal management through a thermal guide, which can be made of thermally conductive materials, facilitates efficient heat dissipation while maintaining directional light control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If LEDs are concentrated in a small area to approximate a point source for directional light control, then light directionality is improved, but thermal management becomes difficult and device complexity increases
Solution Approach 1:
The invention divides the thermal management function into separate components: the heat sink structure is segmented from the optical horn, and multiple LEDs are distributed across different zones rather than concentrated at a single point. This segmentation allows independent optimization of thermal pathways and optical performance.
Solution Approach 2:
The patent transitions from concentrating LEDs in a single point (0D) to distributing them across a two-dimensional array on the circuit board. This dimensional change spreads heat generation over a larger area while the horn structure provides the third dimension for directional light control, resolving the contradiction between point-source optimization and thermal management.
2Temperature
If LEDs are spread out over a larger area for heat dissipation, then thermal management is improved, but light directionality control becomes more difficult
Solution Approach 1:
The horn structure serves multiple functions simultaneously: it acts as an optical element for collimating and directing light from the distributed LED array, while also serving as a thermal management component with integrated heat sink features. This multi-functionality allows the system to achieve both good light directionality and effective heat dissipation from the spread-out LEDs.
Solution Approach 2:
The patent merges the optical horn with the heat sink structure into a single integrated component. The horn's interior surface is designed to reflect and collimate light while its exterior or base portions provide thermal pathways to dissipate heat from the distributed LED array, combining optical and thermal management functions in one structure.
3Temperature
If highly thermally conductive materials and large heat sinks are used for heat removal, then thermal management is improved, but device complexity and size increase
Solution Approach 1:
The heat sink is merged with the horn structure itself rather than being a separate component. The horn material and structure are designed to provide thermal pathways, eliminating the need for additional complex cooling solutions while maintaining effective heat removal from the LED array.
Solution Approach 2:
The horn structure is designed to perform both optical collimation and thermal management functions simultaneously. By making the horn itself thermally conductive and structurally optimized for heat dissipation, the system achieves effective cooling without adding separate cooling components, thereby reducing overall device complexity.
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 dual-horn design effectively collimates light and manages heat, enabling controlled light distribution and thermal dissipation, thus addressing the thermal management challenges of densely packed LEDs while maintaining directional control.
Implementation Method 1
a first interior reflective surface forming a first interior volume... a second exterior reflective surface... The first and second horns at least partially collimate light from the light source transmitted between the first interior reflective surface and the second exterior reflective surface
Implementation Method 2
integrated thermal management through a thermal guide, which can be made of thermally conductive materials, facilitates efficient heat dissipation
Data Source
AI summary
A light collimating horn assembly having two horns, one contained within the other. The horns have reflective surfaces facing each other. A light source, such as a ring of light emitting diodes, is located between the reflective surfaces of the horns. The horns at least partially collimate light from the light source transmitted between the reflective surfaces and exiting from the horns. The horns can be configured to provide controlled collimation in order to substantially collimate light for a spot light or partially but not substantially collimate light for a flood light.