LED Lighting System with Single Gasket Seal and Heat Fins
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Solution Overview
Problem
Current vehicle lighting systems face challenges in providing effective external illumination while maintaining durability and preventing water, dirt, and dust ingress, as existing designs have multiple points of sealing that can lead to contamination and system failure.
Innovation Solution
The proposed auxiliary lighting system features a housing assembly with a planar surface and a lighting unit comprising a printed circuit board, light emitting diodes, and a cover assembly with a gasket, which minimizes entry points for contaminants by eliminating end caps and using a modular design with adjustable lengths, ensuring a single seal between the lighting unit and the housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple sealing areas are provided with gaskets and end caps, then the lighting system can be enclosed and protected, but the number of points where water, dirt, dust, and other particles can enter increases
Solution Approach 1:
The housing is divided into a front housing portion and a rear housing portion that are joined together, creating a segmented structure that allows for effective sealing at the junction while eliminating the need for end caps. This segmentation enables the lighting module to be positioned between the two portions with a single sealing interface.
Solution Approach 2:
The front housing portion, rear housing portion, and lighting module are combined into an integrated assembly where the lighting module is positioned between the two housing portions. This merging eliminates separate end cap components and reduces the number of sealing interfaces to a single gasket between the front and rear housing portions.
2Stability of the object's composition
If end caps are used to enclose the housing, then the housing is fully enclosed, but the number of sealing points increases providing more entry points for contaminants
Solution Approach 1:
The end caps are completely removed from the design. Instead of using end caps to enclose the housing, the invention uses a single gasket sealed junction between the front housing portion and rear housing portion to achieve full enclosure without the additional sealing points that end caps would create.
3Object-affected harmful factors
If a single gasket seal is used between front and rear housing portions, then the number of contaminant entry points is minimized, but the structural complexity of the housing assembly must be managed
Solution Approach 1:
The housing is segmented into front and rear portions that can be separately manufactured and then assembled with a single gasket seal. This segmentation simplifies the overall structure by reducing the number of sealing components while maintaining effective enclosure.
Solution Approach 2:
The single gasket between the front and rear housing portions serves multiple functions: it provides the primary seal against contaminants, structural support for the lighting module positioning, and enables the modular assembly of the housing components. This multi-functionality reduces the need for additional specialized sealing components.
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 enhances durability and prevents contamination by reducing the number of entry points for water, dirt, and dust, while maintaining efficient illumination and heat dissipation, ensuring reliable operation in various environments.
Implementation Method 1
a lighting module having a printed circuit board and a plurality of light emitting diodes operatively connected to the printed circuit board
Implementation Method 2
a rear portion formed by a plurality of heat dissipating fins
Data Source
AI summary
An auxiliary lighting system includes a housing assembly having a generally planar surface and a lighting unit. The lighting unit includes a lighting module having a printed circuit board and a plurality of light emitting diodes operatively connected to the printed circuit board and a cover assembly including a protective cover, a frame, and a gasket. The lighting unit is assembled such that fasteners connect the frame, the protective cover, and the planar surface of the housing assembly to hold the lighting module between the protective cover and the planar surface and hold the gasket between the protective cover and the planar surface.