Nicheless Pool Light Assembly With Thermal Conduction and Sealing
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Solution Overview
Problem
Nicheless lighting assemblies for swimming pools and spas face challenges in heat dissipation due to their smaller surface area and lack of metallic surfaces for thermal conduction, increasing the risk of electrical shock and reducing heat dissipation efficiency.
Innovation Solution
Incorporation of metallic heat sinks and spreaders with overmolded thermally-conductive plastic material onto lenses and heat spreaders, allowing the use of metals like aluminum while maintaining non-conductive external surfaces, and a single sealed joint to prevent water intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If nicheless lighting assemblies use smaller surface area and omit metallic surfaces, then electrical shock risk is reduced, but heat dissipation ability deteriorates
Solution Approach 1:
The patent introduces a thermally-conductive plastic as an intermediary material that bridges the LED heat source and the external environment. This plastic material has high thermal conductivity to efficiently transfer heat away from the LEDs, while simultaneously maintaining electrical non-conductivity to prevent water conduction and electrical shock risks. This intermediary solution resolves the contradiction by providing a material that performs the heat dissipation function of metal without the harmful electrical conductivity when wet.
2Device complexity
If nicheless lights omit lenses to simplify structure, then manufacturing complexity is reduced, but heat dissipation surface area is further decreased
Solution Approach 1:
The patent makes the lens multi-functional by giving it both its traditional optical function (light transmission and diffusion) and a thermal management function (heat dissipation). The lens is designed with increased surface area and is positioned to expose part of its exterior surface to water, allowing it to act as an additional heat dissipation surface. This resolves the contradiction by making the lens serve dual purposes: maintaining optical performance while actively contributing to thermal management without adding structural complexity.
3Reliability
If multiple sealed joints are used to prevent water intrusion, then water-resistance is improved, but production assembly speed deteriorates
Solution Approach 1:
The patent combines multiple sealing functions into a single integrated sealed joint structure. Rather than requiring separate seals for different components (such as separate seals for LED array attachment and lens attachment), the design merges these sealing requirements into one comprehensive sealed joint that prevents water intrusion at all critical interfaces simultaneously. This reduces the number of assembly steps and sealing operations required, thereby improving production assembly speed while maintaining robust water-resistance properties.
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 heat dissipation and water-resistance, reducing the risk of electrical shock and improving assembly efficiency by using aluminum for thermal conductivity without exposing it to water, and minimizing water intrusion points.
Implementation Method 1
a thermally-conductive plastic covering a backside of the lighting assembly
Implementation Method 2
Incorporation of metallic heat sinks and spreaders with overmolded thermally-conductive plastic material onto lenses and heat spreaders
Data Source
Figure 1
Figure 1A
Figure 2
AI summary
Nicheless lighting assemblies principally for swimming pools and spa are detailed. The lighting assemblies include features configured to dissipate heat. The assemblies additionally are designed to reduce possibility of water intrusion.