LED Lighting Assembly with Thermal Fins and Optics Panel
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Solution Overview
Problem
Current lighting systems for externally illuminating signs, such as billboards, face challenges in evenly distributing light, leading to 'hot spots' and inefficiencies, while also struggling with heat dissipation and environmental protection of LEDs.
Innovation Solution
A lighting assembly featuring a thermally conductive back panel with fins for heat dissipation and an optics panel that directs light evenly across the surface, combined with a light panel mounted on a moisture-resistant substrate, ensuring consistent and reliable illumination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional lighting systems are used to illuminate signs, then light can be provided, but light distribution is uneven causing hot spots and inefficiencies
Solution Approach 1:
The lighting system is segmented into multiple individual LED light sources arranged in a grid pattern, with each LED independently controllable. This segmentation allows precise control of light distribution across different zones of the sign, eliminating hot spots by adjusting individual LED output levels to achieve uniform overall illumination.
Solution Approach 2:
Different regions of the lighting array can have different operational characteristics - individual LEDs or groups of LEDs can be dimmed, brightened, or turned off based on local requirements. This local quality control enables optimization of light distribution uniformity while maintaining energy efficiency by applying appropriate illumination levels only where needed.
2Illumination intensity
If LEDs are mounted in outdoor environments, then sign illumination is achieved, but LEDs are exposed to moisture and environmental damage
Solution Approach 1:
A protective enclosure with IP65 or higher rating is used to seal the LED array and electronics from environmental exposure. This protective shell allows the LEDs to be mounted in outdoor locations while preventing moisture and contaminants from reaching the sensitive electronic components, enabling reliable sign illumination in harsh environments.
Solution Approach 2:
The protective enclosure acts as an intermediary barrier between the LEDs and the outdoor environment. It transmits the necessary electrical connections while blocking harmful environmental factors like moisture, dust, and temperature extremes, allowing the LEDs to function reliably in outdoor settings without direct exposure to damaging conditions.
3Power
If LEDs generate heat during operation, then light is produced, but heat accumulation can damage components
Solution Approach 1:
A thermally conductive intermediary material, such as a heat sink or thermal interface material, is placed between the LED modules and the mounting structure or air flow path. This intermediary efficiently transfers heat away from the LEDs, maintaining lower operating temperatures while preserving full light output capability, thus preventing heat-related component damage.
4Adaptability or versatility
If individual LEDs are used in the array, then flexibility and control are improved, but system complexity increases
Solution Approach 1:
The system controls individual LEDs by changing electrical parameters such as current level or pulse width modulation duty cycle for each LED or group of LEDs. This parameter-based control provides flexible adaptability for different lighting scenarios while maintaining relatively simple hardware architecture, as the same LED array can be reconfigured for different effects by simply changing control parameters rather than physical connections.
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 provides even illumination with reduced 'hot spots', enhances heat dissipation, and protects LEDs from environmental conditions, ensuring consistent and reliable lighting with redundancy to maintain uptime.
Implementation Method 1
An extruded substrate formed of a thermally conductive material is provided, the substrate having a plurality of fins extending from a first side of the substrate
Implementation Method 2
At least some of the fins include a hole formed through the fin to enable heated air to rise through the fins
Implementation Method 3
A plurality of LEDs are mounted on a second side of the substrate, and oriented in a longitudinal orientation with the fins oriented parallel to the bottom edge of a surface to be illuminated, such that heat rises perpendicular to the surface of the fin
Data Source
AI summary
A lighting apparatus includes a circuit board and light emitting diodes (LEDs) attached to the circuit board. The LEDs are arranged in an array of row and columns and are attached to the circuit board are arranged in a single plane. A support substrate supports the circuit board. Optical elements are configured to redirect light from the plurality of LEDs. Each optical element is substantially the same as all other optical elements. Each LED is associated with a single optical element and each optical element is associated with a single LED. The lighting apparatus is configured to direct light away from the circuit board so that the light is directed so as to illuminate a substantially rectangular area that is off-center relative to the light assembly. The substantially rectangular area has an edge that is at least 14 feet in length.