LED Light Source Assembly Retrofit for Concave Reflector Fixtures
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Solution Overview
Problem
Existing LED lighting fixtures for theater, architectural, and television applications face challenges in being cost-effective retrofits for incandescent lamp fixtures, as they often require excessive replacement structures and have poor soft focus characteristics due to inefficient integration of LED arrays within the existing fixtures.
Innovation Solution
A light source assembly is designed for attachment to lighting fixtures with a concave reflector, featuring multiple LED assemblies, a heat sink, and an elongated support that aligns the LED arrays with the reflector's focal region, utilizing a heat pipe with a graded wick for efficient heat dissipation and a fastener assembly for easy installation, allowing for efficient light projection and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If LED arrays are substituted for incandescent lamps in existing fixtures, then energy efficiency is improved, but the fixture requires excessive replacement structure and cannot be easily installed with the fixture in situ
Solution Approach 1:
The LED light source assembly is divided into separate functional modules: LED arrays mounted on a support structure, a heat sink assembly, and a fastener assembly. This segmentation allows each component to be optimized independently and facilitates easy installation by replacing only the light source assembly while leaving the existing fixture structure intact.
Solution Approach 2:
The fastener assembly is designed to interface with standard fixture mounting structures, allowing the LED light source assembly to be universally installed in existing fixtures without requiring custom modification. The support structure serves multiple functions: mechanical support for LED arrays, thermal conduction path to the heat sink, and alignment feature for the fixture's optical system.
2Duration of action of stationary object
If LED arrays are substituted for incandescent lamps, then lifetime is improved, but frequent servicing is still required due to heat management needs
Solution Approach 1:
The heat sink is integrated directly with the support structure that holds the LED arrays, creating a unified thermal management system. This merging ensures efficient heat transfer from the LED junctions through the support structure to the heat sink, reducing thermal stress on the LEDs and extending their operational lifetime while minimizing maintenance requirements.
3Loss of energy
If LED arrays are mounted at the rear end of a mixing tube assembly, then energy efficiency is improved, but soft focus characteristics deteriorate because the LED array is imaged in the far field
Solution Approach 1:
The support structure is designed with predetermined geometry that pre-conditions the light paths from the LED arrays before they reach the mixing tube and lens assembly. The support structure's shape and positioning are optimized in advance to ensure that light rays converge appropriately at the fixture's focal point, producing soft focus characteristics without requiring additional optical elements or complex alignment procedures.
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 enables a cost-effective retrofit of incandescent lamp fixtures with improved light distribution and reduced maintenance needs, utilizing a significant portion of the existing fixture structure while providing enhanced far-field integration and energy efficiency.
Implementation Method 1
heat pipe with a graded wick for efficient heat dissipation
Implementation Method 2
heat pipe with a graded wick
Implementation Method 3
light emitted by the lamp is reflected in a forward direction by the concave reflector
Implementation Method 4
the lens assembly in turn projects the reflected light forward along the fixture's longitudinal axis
Data Source
AI summary
An improved LED light source assembly is described, suitable for use as a retrofit for prior lighting fixtures of a kind including a concave reflector, an incandescent lamp positioned with its filament(s) at or near a focal region of the reflector, and a lens assembly for projecting light reflected by the reflector to a distant location, e.g., a theater stage. The improved LED light source assembly includes a compact arrangement of three or more LED assemblies, which are mounted at the forward end of an elongated heat pipe. The heat pipe's rearward end attaches to a heat sink mountable on the back side of the lighting fixture's concave reflector, and the heat pipe extends through a central hole in the reflector to position the LED assemblies at or near the concave reflector's focal region. The concave reflector reflects light emitted by the LED assemblies forward to the lighting fixture's lens assembly, which in turn projects a beam of light to a distant location. The LED light engine's configuration allows a significant proportion of the prior lighting fixture to continue to be utilized, leading to substantial cost saving and simplified installation.