Headlamp Lens Heat Sink and Wire Heating Element
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Solution Overview
Problem
Existing lighting systems with LED lamps face issues with water-based contamination, such as snow or ice accumulation on optical lenses, which can lead to premature deterioration of LED circuits and reduced performance due to elevated temperatures.
Innovation Solution
The implementation of a mechanism that utilizes heat from LED emitters or resistive heating elements to prevent water-based contamination, combined with an optically clear thermal transfer fluid to maintain the lens area at a temperature that inhibits ice formation and extends the lifespan of LED components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If heat-generating devices (LEDs) are used for illumination, then lighting function is achieved, but elevated temperatures cause premature deterioration of LED circuits and reduced performance
Solution Approach 1:
The patent converts the harmful heat generated by LEDs into a beneficial function by directing it to melt snow and ice on the lens. The heat that would otherwise cause premature deterioration is redirected to serve the dual purpose of illumination support and contamination removal, thereby extending LED circuit lifespan while maintaining lighting function.
Solution Approach 2:
The patent introduces an intermediary mechanism (heating elements or heat redirection system) between the heat-generating LEDs and the lens to transfer thermal energy specifically to the lens area. This intermediary allows heat to be moved from the LED circuit to the lens without causing excessive temperature rise in the LED components themselves.
2Object-affected harmful factors
If conventional heating methods are used to prevent snow/ice accumulation on lens, then water-based contamination is removed, but additional energy consumption and device complexity increase
Solution Approach 1:
The system uses the heat already generated by the LED operation itself to prevent snow and ice accumulation on the lens. Rather than requiring separate heating elements powered by additional energy sources, the LED's operational heat is redirected to serve the contamination prevention function, making the system self-sufficient and eliminating extra energy consumption.
Solution Approach 2:
The patent makes the heat-generating LED system multi-functional by having it simultaneously perform illumination and contamination prevention. The same heat source that is necessary for maintaining LED operational temperature is also used to melt snow and ice on the lens, eliminating the need for separate heating systems and reducing overall energy consumption.
3Object-affected harmful factors
If heat is directed to the lens to prevent ice formation, then water-based contamination is prevented, but heat-generating devices may overheat and deteriorate
Solution Approach 1:
The patent uses an intermediary heat transfer mechanism to move thermal energy from the heat-generating LED components to the lens. This intermediary system (such as heat sinks, heat pipes, or redirected convection currents) allows heat to be transferred efficiently to the lens area while preventing excessive temperature accumulation in the LED components, thereby protecting them from overheating and deterioration.
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
Effectively prevents water-based contamination on LED lamp lenses, ensuring optimal performance and extending the useful life of LED circuits by maintaining the lens area at a temperature that prevents ice accumulation while also dissipating heat away from heat-generating components.
Implementation Method 1
uses some of the heat created by a LED emitter or other heat-generating devices within the headlamp assembly
Implementation Method 2
An optically clear thermal transfer fluid may be utilized in the interior of a LED lamp to heat the lens structure
Implementation Method 3
one or more resistive heating elements, in the interior of the headlamp may be utilized in conjunction with heat radiating from the LED
Data Source
AI summary
A headlamp assembly having a mechanism for reducing water based contamination is disclosed. A headlamp assembly includes a lens affixed to a housing having an inner surface and an outer surface, a wire heating element embedded within the inner surface of the lens, wherein the wire heating element is electrically coupled to a circuit board. An encapsulation layer is disposed over the wire heating element and a thermistor is affixed to the lens for sensing when the lens reaches a predetermined condition. The thermistor is electrically coupled to the circuit board and a micro-controller is provided for activating or deactivating the wire heating element based on the predetermined condition sensed by the thermistor.