Modular LED Platform with Open-Air Heat Sink for Debris Management
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Solution Overview
Problem
LED lighting systems with chip-on-board (COB) technology face challenges with heat dissipation and debris accumulation, leading to reduced lifespan and potential damage from snow and ice buildup, which increases manufacturing costs and safety risks.
Innovation Solution
A modular LED platform with an 'open air' heat sink design that allows for efficient heat distribution and snow/ice melting, preventing debris accumulation through rain washing, and integrating video modules with adjustable lens direction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional housing with fins is used for heat dissipation, then heat can be dissipated from the LED assembly, but debris material and moisture can collect on and enter the housing area, causing fins to become clogged and lose functionality
Solution Approach 1:
The patent removes the traditional enclosed housing structure with fins and extracts only the essential heat dissipation function. The LED assembly is mounted directly to a heat sink that exposes the heat dissipation surfaces to the environment without enclosing them in a housing that can collect debris. This extraction of the housing element eliminates the clogging problem while maintaining heat dissipation through direct thermal conduction from the LED to the heat sink.
Solution Approach 2:
The patent employs a heat sink design with porous or open-cell structure that allows air flow through the material while preventing debris accumulation. The porous structure provides large surface area for heat dissipation while the open cells prevent clogging by allowing debris to pass through rather than accumulate on solid surfaces.
2Illumination intensity
If additional LED units or light engines are added to increase emitted light, then light intensity increases, but additional housing structure is required which increases weight and susceptibility to snow and ice buildup
Solution Approach 1:
The patent divides the lighting system into modular LED assemblies that can be independently mounted to the heat sink. Each LED unit is a separate module that can be added or removed without requiring additional housing structure. This segmentation allows light intensity to be increased by adding more LED modules while maintaining a constant weight heat sink structure, eliminating the proportional weight increase that would occur with additional housing.
Solution Approach 2:
The heat sink structure serves multiple functions: it provides thermal management for all LED units, acts as the mounting structure for multiple LED modules, and functions as the complete external housing. This multi-functionality eliminates the need for separate housing structures for each LED unit, preventing weight multiplication while accommodating multiple light sources.
3Productivity
If housing is extended to accommodate additional LED engines, then more light can be emitted, but debris and snow/ice are more prone to build up on the upper portion, causing potential damage or breakage
Solution Approach 1:
The patent extracts the housing function from the system entirely, mounting LED assemblies directly to the heat sink which is then mounted to the mounting structure. This elimination of extended housing removes the surfaces where snow and ice would accumulate, preventing the harmful effects of ice buildup while maintaining the ability to emit high levels of light through multiple LED modules.
Solution Approach 2:
Instead of extending housing outward to accommodate more LEDs (which creates ice accumulation surfaces), the patent inverts the approach by mounting LEDs directly to the heat sink which is attached to the mounting structure. This reversal of the traditional housing-LED arrangement eliminates the problematic extended surfaces while maintaining light output capability.
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 modular design enhances heat dissipation, reduces debris accumulation, and maintains weight below 30 pounds, increasing reliability and safety while reducing manufacturing costs and potential damage from snow and ice.
Implementation Method 1
heat sink design that allows for efficient heat distribution
Implementation Method 2
efficient heat distribution
Implementation Method 3
allows for snow/ice melting
Implementation Method 4
preventing debris accumulation through rain washing
Data Source
AI summary
A modular light assembly having a control housing surrounding a power driver and at least one modular component. The modular component includes two side portions, a plurality of ribs extending between the two side portions to form a grated portion, and a flat portion configured to receive a COB LED. The lighting assembly may also comprise a video assembly having a camera and control circuitry provided within the lighting and video assembly for remotely controlling the camera.