Pipe Relining Light Head With Fluid-Cooled LED Plates
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Solution Overview
Problem
Existing light heads for pipe relining are prone to overheating due to inefficient heat transfer from LEDs to metallic elements, are not suitable for bent or angled pipes, and are costly to manufacture, especially when made of metal.
Innovation Solution
A light head design featuring a plastic body with lateral channels and spacers that allow direct fluid flow to cool LEDs, reducing the need for high thermal conductivity materials and enabling the use of plastic for the body, which is easier to process and less expensive, while also being suitable for smaller and more complex pipe geometries.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metallic elements are used for heat transfer from LEDs, then heat dissipation is improved, but manufacturing cost and processing difficulty increase
Solution Approach 1:
The patent replaces the metallic heat transfer system with a fluid-based cooling system. Instead of relying on thermal conduction through metal components, the invention introduces a pump-driven fluid circulation system that transfers heat from LEDs through fluid convection and heat exchange, thereby eliminating the need for expensive metal heat sinks and simplifying manufacturing.
Solution Approach 2:
The invention changes the cooling mechanism from solid-state thermal conduction to fluid-based heat transfer. By introducing a working fluid and circulation system, the patent transforms the heat dissipation approach, allowing the use of non-metallic materials for LED mounting while maintaining effective temperature control through fluid dynamics.
2Illumination intensity
If elongated light head structure is used, then LED coverage is improved, but device gets stuck in pipe and cannot navigate bends
Solution Approach 1:
The patent divides the light head into multiple modular segments that can flex relative to each other. This segmentation allows the light head to navigate bends and angles in pipes while maintaining LED coverage. Each segment contains LEDs and can be positioned to illuminate different sections of the pipe interior.
Solution Approach 2:
The invention introduces dynamic flexibility to the light head structure, allowing it to adapt its shape as it moves through the pipe. The light head can bend and flex to follow the pipe's geometry, ensuring continuous illumination and curing capability throughout the pipe length, including curved sections.
3Strength
If metallic body is used for structural integrity, then strength is improved, but processing difficulty and cost increase
Solution Approach 1:
The patent employs composite material construction for the light head body, combining materials that provide both structural integrity and ease of manufacturing. The body may use reinforced polymers or composite structures that achieve the required strength without the processing difficulties and costs associated with metal fabrication.
Solution Approach 2:
The invention adopts a disposable or single-use light head design where the body is made from inexpensive, easily manufactured materials. Rather than requiring durable, expensive metals, the light head can be discarded after use, eliminating the need for high-strength materials and complex manufacturing processes.
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 design effectively cools LEDs, prevents overheating, and reduces manufacturing costs, allowing the light head to be used in smaller and more complex pipe configurations, including kitchen and sewer pipes with bends and angles, while maintaining efficient resin curing.
Implementation Method 1
On the apparatus's outer wall is a plurality of light emitting diodes (LEDs) for irradiating the liner to cure the resin in the liner
Implementation Method 2
irradiating the liner to cure the resin in the liner
Implementation Method 3
fluid from the fluid inlet passes through the at least one lateral channel of the body such that the fluid hits the second surface of the LED-plate
Data Source
Figure 1~2
Figure 3
Figure 4A~4B
AI summary
A light head (100) for use in relining a pipe is disclosed. The light head comprises a proximal end cap (104) with a fluid inlet, a distal end cap (108), and at least one body (110a, 110b) arranged between the proximal end cap (104) and the distal end cap (108). The body (110a, 110b) has a longitudinal passage extending from the proximal end cap (104) to the centre of the body (110a, 110b), and wherein at least one lateral channel is extending laterally from the longitudinal passage to an outlet on a lateral outer side of the body (110a, 110b), at least one LED-plate (140) having a first surface and a second surface, wherein the first surface comprises at least one light emitting diode (LED) in order to emit light from the light head (100) towards the pipe, and wherein the LED-plate (140) is arranged on the lateral outer side of the body (110a, 110b) over the outlet, at least one spacer (130) between the LED-plate (140) and the body (110a, 110b) in order to create a gap between the plate (140) and the body (110a, 110b), and wherein the longitudinal passage is configured to receive fluid from the fluid inlet such that in use fluid from the fluid inlet passes through the at least one lateral channel of the body (110a, 110b) such that the fluid hits the second surface of the LED-plate (140), and exits through the gap caused by the at least one spacer (110a, 110b).