Inground LED Light External Adjustment and Thermal Management
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Solution Overview
Problem
Existing inground LED lighting systems face thermal management issues and require manual adjustment, leading to potential water intrusion and premature failure.
Innovation Solution
Inground LED lighting units with external adjustment mechanisms and thermal management features, such as thermally conductive materials and an annular gap for convective cooling, allowing heat dissipation without opening the sealed module, and enabling tilt angles up to 25 degrees from vertical.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the light structure is opened for manual adjustment, then the aiming can be adjusted, but water intrusion and dirt contamination occur leading to premature failure
Solution Approach 1:
The adjustment mechanism is segmented into external and internal components. The external adjustment mechanism allows users to change the aiming direction without opening the sealed light structure, while the internal mechanism remains protected inside the sealed housing, thus maintaining sealing integrity while providing adjustment capability.
Solution Approach 2:
An intermediary transmission mechanism is introduced between the external adjustment input and the internal lighting assembly. This intermediary allows the adjustment motion to be transmitted through the sealed barrier without compromising the seal, enabling external control while maintaining protection against water and dirt.
2Temperature
If thermally conductive materials are used for thermal management, then heat dissipation is improved, but the device complexity increases
Solution Approach 1:
The thermal management function is merged with the existing housing structure. Thermally conductive materials are integrated into the housing components that already exist in the device, combining the structural and thermal management functions into a single integrated design, thus improving heat dissipation without significantly increasing device complexity.
Solution Approach 2:
The housing structure is given multiple functions: it provides mechanical support, protection, and thermal management. By making the housing thermally conductive, it serves as both a structural component and a heat dissipation pathway, eliminating the need for separate thermal management components and reducing overall device complexity.
3Reliability
If the LED module is sealed for protection, then water intrusion is prevented, but thermal management becomes difficult
Solution Approach 1:
A thermally conductive intermediary material is introduced between the LED heat source and the sealed housing. This intermediary efficiently transfers heat from the LEDs to the housing while maintaining the seal's protective function, thus resolving the conflict between sealing for protection and heat dissipation.
Solution Approach 2:
The housing structure is made composite, combining materials with different properties: the outer housing material provides sealing and protection, while thermally conductive materials are integrated within to provide heat dissipation pathways. This composite structure allows the sealed housing to simultaneously protect against water intrusion and manage thermal heat.
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
Enhanced thermal management extends the service life of LEDs, prevents water intrusion, and allows for minor disassembly for upgrades, maintaining performance equivalent to traditional lighting systems.
Implementation Method 1
Heat from the LEDs and/or LED mounting assembly can be transferred to the outside air or internal heat conducting structures while the module is tilted
Implementation Method 2
the presence of an annular gap (doughnut) between the outer housing and the surrounding concrete/cement, thus providing a desired space/volume for air floor (and convective cooling)
Data Source
AI summary
A lighting device having a support module supporting LEDs and having an outer perimeter defining a curved portion, and a housing with an inner surface having a curved portion configured to receive the curved portion of the support module to enable the disk to be aimed, while the curved portions of the disk and housing remain in contact. Optional adjustment means facilitate aiming of the support module without the need to open the sealed LED module.