Extruded LED Floodlight Housing with Vertical Ventilation Ducts
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Solution Overview
Problem
Existing LED floodlights face challenges in efficiently dissipating heat, particularly in large quantity-of-light applications, leading to overheating and increased costs due to the need for heavy radiation structures or complex forced cooling systems, which complicates installation and increases production and maintenance costs.
Innovation Solution
The LED floodlight design incorporates a main unit formed by extrusion molding of a lightweight metal with a concave groove and ventilating ducts that create a chimney effect for heat dissipation, utilizing a bulk metal heat capacity and natural air cooling with radiation fins, eliminating the need for heavy materials and complex cooling systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heavy radiation structures or complex forced cooling systems are used to dissipate heat, then heat dissipation efficiency is improved, but device weight and structural complexity increase
Solution Approach 1:
The patent implements natural convection cooling where the housing structure itself serves as the heat dissipation system. Hot air rises through vertically arranged ventilation holes without requiring external fans or forced cooling mechanisms, allowing the device to cool itself passively through its own thermal buoyancy
Solution Approach 2:
The housing structure performs multiple functions simultaneously: it provides mechanical protection for the LED components while also serving as the heat dissipation pathway through integrated ventilation holes. The same structural elements that form the device enclosure also function as the cooling system
2Temperature
If heavy radiation structures are used to dissipate heat, then heat dissipation efficiency is improved, but device weight increases
Solution Approach 1:
The housing material and structure itself provides the heat dissipation function through naturally circulating air flows. No additional heavy radiation structures or external cooling components are needed, as the device utilizes its own structural elements for thermal management
Solution Approach 2:
The patent changes the arrangement parameters of ventilation holes from horizontal to vertical orientation, exploiting the natural parameter of hot air rising to create effective heat dissipation without adding weight. This parameter change enables passive cooling that is as effective as active cooling systems
3Temperature
If complex forced cooling systems are used, then heat dissipation efficiency is improved, but ease of assembly and installation deteriorates
Solution Approach 1:
The housing structure integrates multiple functions including mechanical protection, air circulation pathways, and heat dissipation. This multi-functionality eliminates the need for separate cooling components that would complicate assembly and installation procedures
Solution Approach 2:
The device automatically establishes natural convection currents through its vertical ventilation hole arrangement without requiring external power sources, control systems, or complex assembly procedures. The cooling system activates automatically based on thermal buoyancy principles
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 design effectively prevents overheating of LEDs, reduces production and maintenance costs, and provides a lightweight, easy-to-assemble floodlight with efficient natural air cooling, ensuring reliable operation and energy savings.
Implementation Method 1
The main unit 1 is configured such that the LED unit 6 is turned on in a posture where the longitudinal direction of the ventilating duct 2 defines a vertical direction, thereby achieving a chimney effect by which heat conducted from the LED unit 6 is transferred to the airflow 8 going up through the ventilating duct 2
Implementation Method 2
an area 1D having a large heat capacity is provided between the inner bottom wall 1F to which the LED unit 6 is attached and the ventilating duct 2
Implementation Method 3
utilizing a bulk metal heat capacity and natural air cooling with radiation fins
Implementation Method 4
natural air cooling with radiation fins
Data Source
Figure 1(a)~1(b)
Figure 2(a)~2(b)
Figure 3
AI summary
It is an object of the invention to provide a light-weight LED floodlight that has a relatively simple structure and is easy to assembly without recourse to any complicated heat radiation structure or forced cooling means. The LED floodlight includes a main unit (1) that is longitudinally formed by extrusion molding of a metal material and has in one side an opening of a concave groove having a U-shaped lateral section, and one or more LED units (6) attached to a central portion of an inner bottom (1F) defining the concave groove in the main unit. The main unit (1) is formed on a back side of the inner bottom wall (1F) of the concave groove (1E) by the extrusion molding and has one or more ventilating ducts (2) that are parallel with the extrusion molding direction and are open at upper and lower ends. An area (1D) having a large heat capacity is provided between the inner bottom wall (1F) to which the LED unit (6) is attached and the ventilating duct (2). The main unit (1) is configured such that the LED unit (6) is turned on in a posture where the longitudinal direction of the ventilating duct (2) defines a vertical direction thereby achieving a chimney effect by which heat conducted from the LED unit (6) is transferred to an airflow going up through the ventilating duct (2).