Sealed Polymer Housing for Underwater Light Heat Dissipation

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Solution Overview

Problem

Conventional underwater lighting for pools and spas faces challenges in heat dissipation due to the use of metal components, which are both thermally conductive and electrically conductive, requiring complex and costly grounding solutions, limiting the use of luminaires from different manufacturers.

Innovation Solution

A sealed polymer housing with thermally conductive and electrically insulative materials is used, incorporating heat-radiating structures and a watertight design to dissipate heat while preventing electrical conduction, along with a method of manufacturing that includes forming a rear housing component from these materials and attaching an electronic assembly with a lens to create a watertight seal.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If metal components are used for heat dissipation, then thermal conductivity is improved, but electrical conductivity increases requiring complex grounding solutions

Engineering Contradiction:

Improveheat dissipationVSAvoidelectrical safety

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent uses a polymer housing material that combines thermal conductivity with electrical insulation properties. This composite material allows heat to be effectively dissipated from the luminaire while simultaneously providing electrical insulation, eliminating the need for complex grounding interfaces between the luminaire and niche.

Inventive Principle:

Principle #40Composite materials

2Temperature

If metal heat sinks are used, then heat dissipation is improved, but device complexity increases due to grounding requirements

Engineering Contradiction:

Improveheat dissipationVSAvoidgrounding interface

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The polymer housing material serves dual functions as both heat dissipation pathway and electrical insulation barrier, eliminating the need for separate grounding interfaces and reducing overall device complexity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The housing material performs multiple functions simultaneously: structural support, heat dissipation, and electrical insulation. This multi-functionality eliminates the need for additional grounding components and simplifies the overall system design.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If metal components are used, then thermal management is improved, but manufacturing cost increases

Engineering Contradiction:

Improveheat dissipationVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The polymer housing material provides both thermal management and electrical insulation in a single component, reducing the number of parts needed and simplifying manufacturing processes, thereby lowering overall manufacturing costs.

Inventive Principle:

Principle #40Composite materials

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

This solution allows for effective heat dissipation without the need for electrical grounding, enabling the use of underwater lights from different manufacturers and enhancing safety and installation flexibility while maintaining a sealed and insulated system.

Implementation Method 1

at least a portion of the rear housing component conducts heat away from the electronic assembly to cool the electronic assembly

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

thermally conductive and electrically insulative material

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Implementation Method 3

Heat-radiating structures are provided on the rear housing component for dissipating heat conducted by the rear housing component

Methodology Applied

Scientific EffectThermal radiation: Thermal Radiation

Implementation Method 4

a lens mounted to the rear housing component and forming a watertight seal therebetween, the lens and the rear housing component enclosing the electronic assembly

Methodology Applied

Scientific EffectSealing:

Data Source

PatentUS10718507B2Underwater light having a sealed polymer housing and method of manufacture therefor

Publication Date: 2020.07.21 HAYWARD IND INC

AI summary

An underwater light having a sealed polymer housing includes a rear housing component formed at least in part from a thermally conductive and electrically insulative material, an electronic assembly having at least one light-emitting element mounted thereto, the electronic assembly in thermal communication with the rear housing component, and a lens mounted to the rear housing component and forming a watertight seal therebetween, the lens and the rear housing component enclosing the electronic assembly. At least a portion of the rear housing component conducts heat away from the electronic assembly to cool the electronic assembly.