LED Light Fixture Thermal Management via Air Flow Passageway
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Solution Overview
Problem
Conventional commercial light fixtures face limitations such as high cost, low efficiency, high power consumption, and poor light output quality, with LED-based fixtures experiencing performance and efficiency issues due to heat generation, which compromises their reliability and longevity.
Innovation Solution
A multi-use durable light fixture featuring an LED light engine with a rugged housing, internal power supply, and an air flow passageway for improved thermal management, including heat transfer elements and fins for dissipating heat, allowing for efficient heat isolation and increased reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LED light fixtures are used, then energy efficiency and light output quality are improved, but heat generation compromises performance and reliability
Solution Approach 1:
The patent converts the harmful heat generated by LEDs into a beneficial feature by implementing a heat exchange system where LED heat is transferred to preheat incoming air or water, and then cooled by a thermal storage medium. This transforms the waste heat into a useful resource for heating applications while maintaining LED performance through active cooling.
Solution Approach 2:
The patent introduces a thermal storage medium (phase change material) as an intermediary between the LED heat source and the environment. This intermediary absorbs excess heat during high-load periods and releases it during low-load periods, stabilizing LED operating temperature and maintaining performance reliability.
2Reliability
If conventional fluorescent or halogen bulbs are used, then durability and simplicity are maintained, but power consumption is high and efficiency is low
Solution Approach 1:
The patent replaces conventional fluorescent or halogen bulb systems with LED technology coupled with a thermal management system. This substitution eliminates the need for bulky ballasts, starters, and reflectors while providing superior energy efficiency and comparable or improved durability through proper heat management.
Solution Approach 2:
The patent changes the operating parameters of the lighting system by using LEDs that operate at lower voltages and currents compared to conventional bulbs, while the thermal storage system enables continuous operation at optimal parameters regardless of ambient temperature fluctuations, maintaining high efficiency and durability.
3Strength
If substantial housings are used to protect light sources, then durability against physical damage is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The patent segments the housing into distinct thermal zones: an outer protective shell for durability, an intermediate thermal management layer with heat exchangers and phase change materials, and an inner LED mounting section. This segmentation allows the outer housing to provide physical protection while the intermediate layer actively manages heat dissipation.
Solution Approach 2:
The patent introduces thermal management components (heat exchangers, phase change materials, thermal conductive interfaces) as intermediaries between the LED light source and the outer protective housing. These intermediaries create thermal pathways that enable efficient heat dissipation while the outer housing maintains its protective function.
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 enhances the reliability and efficiency of the light fixture by reducing heat-related failures, enabling longer operational life, lower maintenance costs, and increased connectivity options, while being environmentally friendly and aesthetically pleasing.
Implementation Method 1
an air flow passageway across the light engine whereby air flows along the passageway during operation of the light fixture
Implementation Method 2
heat transfer elements positioned between the circuit board and the housing
Implementation Method 3
an arrangement of fins extending rearward from a main body portion of the housing along a spindle that dissipate heat
Data Source
AI summary
An LED light fixture is provided and includes a housing having a main body portion with a rear wall. A plurality of fins integrally extends from an outer surface of the rear wall of the main body portion. A spindle with an internal bore integrally extends from the outer surface of the rear wall of the main body portion wherein the spindle is positioned among the fins. A light engine assembly is positioned within the main body portion and includes a plurality of LED light modules mounted to a printed circuit board. Each module comprises a LED and a lens extending from the printed circuit board, wherein the printed circuit board resides against an inner surface of the rear wall. A separate enclosure configured to enclose power management components is connected to a rear portion of the housing proximate the fins. The enclosure includes a housing wall arrangement and leads that extend through both an opening in the housing wall and the internal bore of the spindle, past the rear wall of the main body portion and to the printed circuit board.