Aircraft Position Light LED Module Universal Mounting
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Solution Overview
Problem
Existing LED systems for aircraft navigation lights are not designed to fit into existing light module housings, making the replacement of incandescent or halogen lamps with LEDs an expensive and time-consuming process.
Innovation Solution
A miniaturized, universal LED module with a 'blade' form factor that meets FAA photometric requirements, optimizing space usage and performance by arranging LEDs and reflectors to maximize angular intensity patterns, allowing for installation in various aircraft wing-tip cavities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing LED systems are used to replace incandescent or halogen lamps, then longer life and lower power consumption are achieved, but the replacement process becomes expensive and time-consuming due to incompatibility with existing light module housings
Solution Approach 1:
The LED light module is designed with a universal mounting structure that can be installed in existing aircraft light module housings designed for incandescent or halogen lamps. The module uses a standardized bayonet-style connector that fits into the existing housing, allowing a single LED module design to replace multiple different lamp types across various aircraft models, thereby reducing replacement cost and time while achieving longer lifespan and lower power consumption
2Ease of manufacture
If LED modules are designed to fit existing light module housings, then replacement cost and time are reduced, but the physical footprint and space usage may be compromised
Solution Approach 1:
The LED light module employs a three-dimensional stacked arrangement of LEDs, reflectors, and lenses that efficiently utilizes vertical space within the housing. Multiple LEDs are arranged in layers along the optical axis, with reflectors and lenses positioned at different depths to optimize light extraction and direction. This dimensional arrangement achieves compact footprint while maintaining compatibility with existing housings
3Illumination intensity
If LED arrangement optimizes angular intensity pattern performance, then photometric requirements are met, but the physical footprint and complexity of the module increases
Solution Approach 1:
The LED light module uses curved or domed lens elements that refract and redirect light to achieve the required angular intensity distribution. The curved lens surfaces are optimized to spread light uniformly across the forward hemisphere while concentrating intensity in specific angular zones, meeting FAA photometric requirements without requiring a large physical footprint. The spherical or hemispherical lens geometry efficiently manipulates light paths in three dimensions
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
Enables efficient and cost-effective replacement of incandescent or halogen lamps with LEDs, providing improved photometric performance and reducing maintenance costs by fitting into existing housings and optimizing light distribution.
Implementation Method 1
Light-emitting-diodes (LEDs) are slowly replacing navigation and position lights on commercial aircraft
Implementation Method 2
Indirect-view reflector orientations maximize reflector light collection and redirection into critical portions of the angular intensity pattern
Data Source
AI summary
An aircraft position light assembly having one or more light emitting diode (LED) modules. The LED module can be installed in a variety of aircraft wing-tip cavities. An example LED module includes a support device that mounts within an aircraft wingtip, a bracket device that attaches to the support device, at least one circuit board that mounts to the bracket, and two pairs of LEDs. Each pair of LEDs is mounted on opposing major surfaces at a first end of the circuit board. A first pair of reflectors is attached to the circuit board adjacent to two of the LEDs on the opposing major surfaces. A second pair of reflectors is attached to the circuit board adjacent to the other two LEDs on the opposing major surfaces.