Resistive Polymer Heater for LED Lens Anti-Icing
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Solution Overview
Problem
LED light assemblies in vehicles face challenges with snow, ice, and fog accumulation on lenses, which can obstruct visibility and require frequent and costly bulb replacements, especially in inclement weather conditions.
Innovation Solution
A heater system incorporating a phase-changing, resistive polymer composite heating element positioned behind the lens, which applies heat to prevent ice and snow buildup, utilizing a resistive layer with a positive temperature coefficient that self-regulates temperature and allows light to pass through, eliminating the need for etching processes and providing a low-profile, adaptable solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heater system is added to prevent ice and snow accumulation on LED light lenses, then visibility and reliability are improved, but device complexity increases
Solution Approach 1:
The heating element is integrated directly into the light assembly housing, merging the heating function with the existing structural components. This eliminates the need for separate heater assemblies and reduces overall system complexity while maintaining the anti-icing function.
Solution Approach 2:
The light assembly housing serves multiple functions: it provides structural support, directs light, and now also houses the heating element for ice and snow prevention. This multi-functionality reduces the number of separate components needed in the system.
2Temperature
If a heating element is positioned close to the lens for effective heating, then heating efficiency is improved, but light transmission is blocked
Solution Approach 1:
The heating element is positioned in a localized area at the rear of the lens rather than covering the entire surface. This localized heating approach provides sufficient thermal energy to prevent ice and snow accumulation without blocking the majority of the light transmission path.
Solution Approach 2:
The heating element is positioned in the depth dimension (rear of the lens) rather than in the optical path plane. This spatial arrangement allows the heating element to be close enough to the lens for effective heating while remaining out of the direct light path, thus maintaining light transmission.
3Use of energy by moving object
If traditional incandescent bulbs are replaced with LEDs, then energy efficiency and lifespan are improved, but cost of replacement and maintenance increases
Solution Approach 1:
The heater system is pre-integrated into the LED light assembly during manufacturing, providing proactive protection against ice and snow accumulation. This preliminary action prevents visibility issues before they occur, eliminating the need for costly field replacements and maintenance interventions.
Solution Approach 2:
The heating element automatically activates when the light assembly is in use, providing self-service protection against ice and snow. This automatic operation eliminates the need for manual intervention or external maintenance, reducing long-term costs despite the initial manufacturing investment.
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 heater system effectively prevents ice and snow accumulation on LED light lenses, ensuring continuous visibility and reducing maintenance costs by integrating into existing LED light assemblies, while maintaining performance and safety in various weather conditions.
Implementation Method 1
A heater system incorporating a phase-changing, resistive polymer composite heating element positioned behind the lens, which applies heat to prevent ice and snow buildup
Implementation Method 2
incorporating a phase-changing, resistive polymer composite heating element
Data Source
AI summary
A heater system for an LED light assembly having a lens and a plurality of LED lights includes a heating element positioned behind and spaced from the lens and having openings aligned with the LED lights for allowing light from the LED lights to pass therethrough.