LED Sign Lighter With Modular Reflectors
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Solution Overview
Problem
Conventional sign lighters are energy-inefficient, have a short lifespan, and suffer from excessive light spill and undesirable yellow tint, with high maintenance costs and striations, while LEDs have not been effectively integrated into sign lighting systems for retrofitting existing installations.
Innovation Solution
An LED sign lighter system featuring a diecast housing with pre-set LED modules, electrical drivers, and a heat sink, including reflectors and weather protection, designed for efficient, long-lasting, and even illumination with minimal light spill, allowing for retrofitting and easy component replacement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If conventional lamps (metal halide) are used in sign lighters, then sufficient illumination is achieved, but energy consumption is excessive and lifespan is short
Solution Approach 1:
The patent changes the fundamental parameters of the light source by replacing conventional metal halide lamps with LED modules. This parameter change achieves both sufficient illumination intensity and dramatically reduced energy consumption, as LEDs are inherently more energy-efficient while providing adequate brightness for sign illumination applications.
Solution Approach 2:
The patent substitutes the conventional lamp-based illumination system with an LED-based system. This replacement eliminates the need for filaments and gas discharge mechanisms, using instead solid-state LED technology that converts electrical energy directly to light with minimal energy loss, thereby reducing energy consumption while maintaining illumination levels.
2Illumination intensity
If conventional lamps (metal halide) are used in sign lighters, then illumination is provided, but lifespan is short and maintenance costs are excessive
Solution Approach 1:
The patent employs modular LED assemblies that can be easily replaced. While individual LEDs have long lifespans, the modular design allows for cost-effective replacement of entire modules rather than individual components, maintaining continuous illumination with minimal downtime and reduced long-term costs compared to conventional lamp systems.
Solution Approach 2:
The patent divides the illumination system into separate modular LED assemblies, each capable of independent operation and replacement. This segmentation ensures that if one module fails, others continue to provide illumination, effectively extending the operational lifespan of the overall sign lighter system while reducing maintenance costs.
3Illumination intensity
If conventional lamps are used in sign lighters, then light is emitted, but excessive light spill occurs illuminating areas beyond the sign
Solution Approach 1:
The patent incorporates individual reflectors for each LED within the modular assemblies, creating localized light control. This local quality approach directs light precisely where needed on the sign while preventing light spill into surrounding areas, as each LED's light is controlled by its own reflector rather than relying on a single large reflector system.
4Illumination intensity
If conventional filament lamps are used, then light is produced, but striations are present in the light output
Solution Approach 1:
The patent replaces filament-based light production with solid-state LED technology. This substitution eliminates the physical filament structure that causes striations, producing smooth, consistent light output without the linear artifacts characteristic of filament lamps, thereby improving light quality stability.
5Illumination intensity
If conventional sign lighters are designed, then illumination is provided, but retrofitting existing installations is not feasible
Solution Approach 1:
The patent designs modular LED assemblies with standardized mounting configurations that can be adapted to various existing sign lighter installations. This universality enables retrofitting of conventional sign lighters with LED technology while maintaining compatibility with different mounting structures and electrical systems, thereby providing both improved illumination and installation flexibility.
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 LED sign lighter provides energy-efficient, reliable, and long-lasting lighting with reduced light spill and no striations, enabling cost-effective maintenance and improved illumination quality, suitable for various applications including roadway signs and billboards.
Implementation Method 1
a heat sink preferably molded into the assembly to help alleviate heat caused by the normal use of one or more LEDs in each LED module
Implementation Method 2
a heat sink preferably molded into the assembly to help alleviate heat caused by the normal use of one or more LEDs
Implementation Method 3
The LED module may further include one or more reflectors or over-optics to control the angle of the light emitted from each LED
Data Source
AI summary
A light emitting diode (LED) sign lighter is positioned to illuminate a sign. One or more LED modules on the LED sign lighter are directed toward different portions of the sign. Each LED module is configured with a reflector or over-optic to control the angle of the light emitted toward the sign. Each LED module includes an array of LEDs. The configuration of each LED module within the LED sign lighter helps to reduce the build-up of environmental contaminants on the LED module. The center section of the LED sign lighter includes a compartment for housing electrical components to power the LED modules. Heat sink fins are oriented along the back side of the LED sign lighter to provide thermal efficiency for the LED modules.