LED Lighting Array for Portable Task Light

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Solution Overview

Problem

Existing portable task lights using LED arrays are inefficient in maximizing illuminative properties and intensity due to fixed layouts and lack of pulsating direct current drive, leading to suboptimal beam disk flux efficiency at varying target distances.

Innovation Solution

A portable task light with an off-axis orientation of LEDs in a pulsed current drive system, allowing adjustable emission planes to optimize illumination patterns and eliminate exclusion zones, thereby enhancing disk flux efficiency at specific target distances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If LED arrays use fixed layouts and continuous current drive, then the structure is simple and reliable, but illumination efficiency and beam disk flux efficiency are suboptimal

Engineering Contradiction:
Improvebeam disk flux efficiencyVSAvoidlayout complexity
Core Design Contradiction:
Illumination intensityVSDevice complexity

Solution Approach 1:

The patent applies the dynamics principle by making the LED emission planes adjustable rather than fixed. The LEDs can be oriented at different angles relative to the tube axis, allowing the illumination pattern to be dynamically optimized for different target distances. This enables the system to achieve higher beam disk flux efficiency by adapting the LED orientations to match the specific application requirements, resolving the contradiction between illumination efficiency and structural simplicity.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent implements periodic action by using pulsed direct current drive instead of continuous current. The pulsed drive circuit operates at a frequency that maximizes LED intensity output, creating periodic illumination cycles that enhance the overall illumination efficiency and beam disk flux efficiency. This periodic operation allows the LEDs to be driven at higher peak currents while maintaining lower average power consumption, thereby improving illumination intensity without excessive heat generation.

Inventive Principle:
Principle #19Periodic action

2Illumination intensity

If LED arrays are mounted on single plane with standard orientations, then manufacturing is simple, but exclusion zones are created at varying target distances

Engineering Contradiction:
Improvearea coverageVSAvoidmounting complexity
Core Design Contradiction:
Illumination intensityVSEase of manufacture

Solution Approach 1:

The patent applies asymmetry by orienting LEDs at different angles relative to the tube axis rather than using uniform orientations. Specifically, LEDs in different columns are angled at different angles (e.g., first column at angle α, second column at angle β, third column at angle γ), creating an asymmetric emission pattern that eliminates exclusion zones and provides uniform illumination coverage across the target area. This asymmetric arrangement allows the light beams to overlap more effectively, covering the entire beam disk area without dark spots.

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent transitions from a two-dimensional planar arrangement to a three-dimensional spatial configuration by mounting LEDs on multiple planes that are angled relative to each other. The first, second, and third columns of LEDs are disposed on different planes with different orientations, creating a three-dimensional emission pattern. This dimensional change allows the illumination to cover a broader area and eliminates the exclusion zones that would exist with planar arrangements, while the modular column structure maintains manufacturing simplicity.

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

3Use of energy by moving object

If portable task lights use traditional power sources like batteries or transformers, then power delivery is reliable, but the device size and weight increase

Engineering Contradiction:
Improvepower efficiencyVSAvoiddevice weight
Core Design Contradiction:
Use of energy by moving objectVSWeight of moving object

Solution Approach 1:

The patent extracts and eliminates the transformer component from the power system by using a pulsed direct current drive circuit that can operate directly from rectified AC power or battery power without requiring voltage transformation. This extraction of the transformer removes unnecessary weight and complexity from the portable task light while maintaining reliable power delivery through efficient pulsed current operation that maximizes LED power conversion efficiency.

Inventive Principle:
Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the electrical operating parameters by using pulsed direct current with specific pulse widths and frequencies optimized for LED operation. The pulsed drive circuit converts AC or battery power into pulsed DC with parameters (pulse width, frequency, duty cycle) that maximize LED light output while minimizing power consumption and heat generation. This parameter optimization improves power efficiency and reduces the energy requirements, thereby reducing the size and weight of the power source needed.

Inventive Principle:
Principle #35Parameter changes

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 results in a compact, lightweight task light with improved illumination efficiency and reduced exclusion zones, maximizing brightness and area coverage at selected target distances, while eliminating the need for transformers and reducing manufacturing and energy costs.

Implementation Method 1

A plurality of light emitting diodes (LED's) are mounted in columns on a planar mounting substrate... Each LED emits light when forward biased

Methodology Applied
Scientific EffectLight emitting diode: Light Emitting Diode

Implementation Method 2

An electrical drive circuit associated with the mounting substrate within the tube provides pulsed direct current for driving the LED's... providing a pulsating forward current which maximizes the LED intensity and the light output therefrom

Methodology Applied
Scientific EffectPulsed current drive:

Data Source

PatentUS7334918B2LED lighting array for a portable task light
Publication Date: 2008.02.26 BAYCO PRODS INC
  • US7334918B2 patent drawing
  • US7334918B2 patent drawing
  • US7334918B2 patent drawing

AI summary

An LED lighting array is disclosed wherein a plurality of light emitting devices disposed in at least first and second columns are mounted on a planar mounting surface to form an emission plane. The emission axes of all the LEDs in a first column are parallel with each other and lie in a first plane. The emission axes of the LEDs in an adjacent, second column are also parallel, but a second plane containing the emission axes of the second column is disposed at a predetermined, non-zero angle with respect to the first plane. The non-zero angle is a function of the LED beam width and the distance to a lighting target. This configuration of the LEDs provides an optimum balance at a predetermined target distance between the size of the area illuminated and the brightness of the illumination of the target. In one aspect of the invention the LED lighting array includes at least first, second and third columns of LEDs. In another aspect of the invention an LED task light includes a transparent tube and an LED lighting array disposed within the tube. An electrical drive circuit associated with the mounting substrate within the tube provides pulsed direct current for driving the LED's.