Modular Tunnel Light Carrier Module Thermal Management
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Solution Overview
Problem
Tunnel lights with LEDs face issues of insufficient cooling capacity and the inability to replace defective components without replacing the entire unit, leading to maintenance challenges and resource wastage.
Innovation Solution
A modular tunnel light design featuring a flat, plate-shaped carrier module with thermally conductive U-shaped retaining profiles, allowing for easy exchange of lighting and control units, along with a detachable housing cover for improved access and cooling, enabling efficient thermal management and tool-free maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a closed luminaire housing with high optical power LEDs is used, then lighting performance is improved, but cooling capacity becomes insufficient
Solution Approach 1:
The luminaire is divided into modular components: a replaceable carrier module containing LEDs and control electronics, and a separate housing. This segmentation allows the housing to be optimized for cooling with open structures while the carrier module can be independently replaced for maintenance
Solution Approach 2:
The carrier module with LEDs and control electronics is extracted as a separate interchangeable component from the housing. This extraction enables the housing to focus on thermal management functions while the removable module handles lighting and control functions
2Reliability
If the entire tunnel light is replaced when components fail, then reliability is maintained, but resource wastage increases
Solution Approach 1:
The luminaire is segmented into a reusable housing and replaceable carrier modules. When LEDs or control electronics fail, only the carrier module needs replacement while the housing remains in use, reducing resource wastage
Solution Approach 2:
Instead of discarding the entire luminaire when components fail, the housing is recovered and reused while only the defective carrier module is discarded or replaced, minimizing material waste
3Ease of manufacture
If the luminaire housing is made as one piece, then manufacturing simplicity is improved, but maintenance complexity increases
Solution Approach 1:
The luminaire is divided into a housing and separate carrier modules that can be independently manufactured and assembled. This segmentation simplifies maintenance by allowing easy removal and replacement of carrier modules without disassembling the entire housing
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
Enhances cooling capacity, simplifies maintenance by allowing quick replacement of components, reduces waste by allowing reuse of the lamp housing, and ensures effective thermal management and optimal light output.
Implementation Method 1
the light sources in the form of Light-emitting diodes are arranged on its upper side, which points towards the housing cover (3), and for cooling purposes are thermally conductively connected to the carrier module (10)
Data Source
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AI summary
The invention relates to a tunnel light (1) comprising a light housing (2) extending along a longitudinal axis (LA) and a housing cover (3) connectable to the light housing (2), which is at least partially transparent and encloses an interior space (4). The interior space (4) contains a plurality of light sources (8) in the form of light-emitting diodes (LEDs) and at least one associated control unit (9) connected to the light sources (8) for controlling the light sources (8). At least one flat, plate-shaped support module (10) extending along the longitudinal axis (LA) with a top and bottom surface (10.1, 10.2) is replaceably mounted in the interior space (4), wherein the light sources (8) in the form of LEDs are arranged on the upper surface (10.1) of the support module, which faces the housing cover (3), and are thermally connected to the support module (10) for cooling purposes.The light sources (8) are associated with at least one lens system (12) for beam shaping. Furthermore, the support module (10) is multi-part and has at least a first support module part (10a) with a top and bottom surface (10.1a, 10.2a) and a second support module part (10b) with a top and bottom surface (10.1b, 10.2b). The light sources (8) are arranged on the top (10.1a) of the first carrier module part (10a) and the at least one control unit (9) is arranged on the bottom (10.2b) of the second carrier module part (10.2), wherein the carrier module parts (10a, 10b) are thermally conductive and interchangeably connected to the luminaire housing (2) via at least two U-shaped retaining profiles (13) and wherein the first carrier module part (10a) including the light sources (8) and the at least one lens system (12) forms an interchangeable assembly and the second carrier module part (10.2) with the control unit (9) forms an interchangeable assembly.