Integrated LED Aircraft Position Light Module Design
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Solution Overview
Problem
Traditional aircraft rear position lighting systems using incandescent lamps have limited lifespan and are costly to maintain, and LED-based systems require complex setups with additional baffles that need redesign for each version, leading to increased costs and potential non-compliance with angular illumination requirements.
Innovation Solution
A single LED light module with integrated reflector and baffle design on a printed circuit board, eliminating the need for external baffles or masking, which allows for a predefined angular illumination pattern without additional components, and can be easily integrated into existing lamp assemblies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If incandescent lamps are used in rear position lighting systems, then the lighting system is simple to implement, but the lifespan is limited and maintenance costs are high
Solution Approach 1:
The patent replaces incandescent lamps (thermal radiation-based mechanical system) with LED modules (electroluminescence-based solid-state system). This substitution extends the lifespan from thousands of hours for incandescent to tens of thousands of hours for LEDs, while maintaining manufacturing simplicity through standardized LED module designs that integrate all necessary components including reflectors and baffles.
2Duration of action of stationary object
If LED-based lighting systems are used, then the lifespan is extended, but the device complexity increases due to requirements for multiple printed circuit boards and external baffles
Solution Approach 1:
The patent merges the LED array, reflector, and baffle into a single integrated LED module assembly. The reflector is formed as an integral part of the module housing, and the baffle is incorporated directly into the module structure rather than being a separate component. This integration eliminates the need for multiple printed circuit boards and external baffles, reducing assembly complexity while maintaining the extended lifespan benefits of LEDs.
3Manufacturing precision
If external baffles are used in LED lighting systems, then angular illumination requirements can be met, but the manufacturing cost increases and redesign is needed for each new version
Solution Approach 1:
The patent designs the LED module with an integrated reflector and baffle structure that can be universally applied across multiple aircraft models and lighting configurations. The modular design allows the same core LED module to be adapted to different applications by simply changing the housing or mounting configuration, rather than redesigning the entire assembly including baffles for each new version. This universality reduces manufacturing costs while maintaining precise angular illumination control.
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
This solution extends the lifespan of aircraft position lights, reduces maintenance costs, and ensures compliance with angular illumination standards by providing a self-contained, adaptable LED light module that meets regulatory requirements without the need for frequent redesigns or additional components.
Implementation Method 1
an aircraft navigation light which comprises a base and circuit board in thermal contact with the base. White and colored LEDs mount on the circuit board.
Implementation Method 2
A reflector-shade placed adjacent the LEDs reflects light from the LEDs in desired directions
Data Source
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AI summary
A rear position light-emitting diode (LED) light module (20) for use on an aircraft. The light module includes a single printed circuit board (PCB) (24), at least one light emitting diode (28) attached to a first surface of the PCB and a single reflector and baffle device (26) attached to the PCB. The single reflector and baffle device provides an illumination pattern having a predefined angular pattern in the first plane. The predefined angular pattern in the first plane is configured to provide an illumination pattern that does not overlap with light illuminated by port and starboard position lights of the aircraft. The single reflector and baffle device includes a base section (50) being planar, the base section comprises a cavity, first and second side sections (60-72) attached to a first surface of the base section on opposing sides of the cavity, the first and second side sections intersect the first plane but not the second plane and a plurality of snap fittings attached to a second side of the base section.