Polycarbonate LED Housing with Integrated Translucent Window
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Solution Overview
Problem
Existing underwater lights face issues with corrosion, leakage, and damage from heat and impact, requiring frequent maintenance and being prone to galvanic corrosion, especially when used in exposed environments like boats or public areas.
Innovation Solution
A lighting apparatus with a plastic housing, specifically made of polycarbonate, that integrates a translucent window and an LED assembly, eliminating the need for a separate sealing arrangement and using a bayonet fitting and O-ring for watertight sealing, along with a heat sink for thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a metal housing with glass window assembly is used, then the light output is good, but the structure is prone to corrosion and leakage
Solution Approach 1:
The patent changes the material parameters from metal housing and glass window to plastic housing and translucent plastic window. This material substitution eliminates galvanic corrosion while maintaining adequate light transmission through the translucent window material, resolving the contradiction between good light output and corrosion/leakage resistance.
Solution Approach 2:
The patent uses composite construction with a plastic housing integrating both structural and sealing functions, combined with a translucent window material that provides both protection and light transmission. This composite approach eliminates the need for separate metal components that would cause corrosion.
2Illumination intensity
If a separate sealing arrangement is used, then the light output is good, but the device complexity increases
Solution Approach 1:
The patent merges the housing and window into a single integrated component. The translucent window is formed as an integral part of the plastic housing, eliminating the need for separate sealing arrangements between metal housing and glass window. This integration reduces device complexity while maintaining light transmission functionality.
3Temperature
If water is used for cooling, then the heat dissipation is good, but the seals are damaged by heat
Solution Approach 1:
The patent extracts the cooling function from the water-based system and replaces it with a heat sink component. The heat sink provides thermal management for the LED assembly without requiring water contact, thereby preventing heat damage to seals while maintaining adequate heat dissipation.
4Illumination intensity
If glass window assembly is used, then the light transmission is good, but the impact resistance is poor
Solution Approach 1:
The patent changes the window material from glass to translucent plastic. This material parameter change maintains adequate light transmission while dramatically improving impact resistance, as plastic materials are inherently more resistant to shock and impact than glass.
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 provides a durable, corrosion-resistant, and leak-proof lighting system that can be easily maintained without raising the boat from the water, allowing for high-intensity lighting without seal damage from heat, suitable for harsh environments.
Implementation Method 1
a heat sink located adjacent the PCB to which the at least one LED is thermally coupled
Implementation Method 2
a light emitting diode (LED) assembly located within the housing to emit light through the translucent window
Data Source
AI summary
A lighting apparatus (2) includes a housing (4) of plastic material, the housing (4) defining a translucent window (12), and a light emitting diode assembly (3) on a printed circuit board (34). The apparatus (2) may be attached to the hull (14) of a boat by means of a flange (10) and a nut (16). The apparatus (2) may include a heat sink (36) machined from a solid aluminum bar. The housing (4) may be connected to a sealing cap (6). The housing (4) is preferably injection-molded from a thermoplastic material such as polycarbonate. Electrical wires may extend through a central bore (42) of the heat sink (36) and the sealing cap (6).