LED Lighting Support Honeycomb Structure Thermal Management
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Solution Overview
Problem
Existing light-emitting diode (LED) lighting devices face issues with temperature gradients, climatic variations, suboptimal sealing, and high production costs due to varying thermal diffuser profiles and sensor interference, particularly in outdoor applications.
Innovation Solution
A lighting device with an improved support structure that allows for adjustable luminous power without changing the thermal diffuser section, incorporates a hollow profile for air cooling and separate electronic boards to isolate sensors, and features a sealed enclosure with a watertight and air-permeable connection to manage temperature and environmental factors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the thermal diffuser profile is varied to accommodate different lighting powers, then the lighting device can handle different power variants, but the production costs increase due to requiring multiple profile variants
Solution Approach 1:
The patent applies universality by designing a single standardized thermal diffuser profile that can accommodate multiple lighting power variants. The support structure is configured with standardized dimensions and mounting features that remain consistent across different power levels, allowing the same profile to serve multiple functions for different LED configurations and power outputs.
Solution Approach 2:
The patent applies segmentation by separating the thermal diffuser profile from the electronic card and LED module. This allows the profile to be designed once as a universal component while the electronic cards and LED modules can be varied independently to create different power variants, reducing the need for multiple customized profiles.
2Device complexity
If sensors are located on the electronic card close to the light-emitting diodes, then the device structure is simplified, but the sensor operation is impacted by LED heat and light interference
Solution Approach 1:
The patent applies the extraction principle by removing the sensors from the electronic card and relocating them to the support structure. This physical separation extracts the sensors from the harmful thermal and optical environment near the LEDs, allowing them to operate reliably while maintaining a relatively simple overall device structure.
3Ease of manufacture
If the transparent cover and support plate are connected in one plane to simplify sealing, then the sealing process is easier, but the cable gland sealing becomes suboptimal
Solution Approach 1:
The patent applies dimensionality change by introducing a stepped configuration where the support plate extends beyond the transparent cover in a radial direction. This creates a second sealing plane at a different dimensional level, allowing cable glands to be sealed effectively without compromising the main cover sealing.
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 enhances thermal management, reduces production costs by allowing multiple power variants from a single diffuser design, and optimizes sensor operation by isolating them from LED heat sources, resulting in improved reliability and efficiency across different environmental conditions.
Implementation Method 1
a hollow profile for air cooling
Implementation Method 2
a substantially planar support plate, an electronic card fixed to the support plate... significant temperature gradients given the high temperature rise of the light-emitting diodes
Data Source
Figure 1~4B
Figure 5~9B
Figure 10~13
AI summary
The object of the invention is a lighting device comprising a support (16), at least one electronic board (148) on which light-emitting diodes are mounted and which is attached to the support (16), a cover that covers the electronic board (148), and a power cable (156) connected to the electronic board (148), characterized in that the support (16) is a metal panel (134) comprising two flat plates (138, 138') and a honeycomb structure (136) interposed between the two flat plates (138, 138'), the honeycomb structure (136) comprising a plurality of conduits, each delimited by at least one wall (140) perpendicular to the plates (138, 138'), and in that the electronic board (148) is attached to a first face (138E) of one of the two plates (138), and a second face (1381) of said plate (138) opposite the first face (138E) being in contact with the alveolar structure (136),a portion of the electrical cable (156) being arranged between the two plates (138, 138').