Polymer Shell Flashlight With Metal Core Heat Bridge

Solution Overview

Problem

High power LED flashlights face challenges with heat management and material limitations, as metal alloy components are heavy and unsuitable for color customization, while polymers offer lightweight options but poor thermal conductivity.

Innovation Solution

A high power LED flashlight design featuring a polymer shell with a metal core and heat bridge thermally coupled to the LED lamp and reflector, eliminating the need for a metal alloy outer housing and enhancing thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If metal alloy housing is used for thermal management, then heat dissipation is improved, but weight increases

Engineering Contradiction:

Improveheat dissipationVSAvoidhousing weight

Core Design Contradiction:

TemperatureVSWeight of moving object

Solution Approach 1:

The housing is divided into two functional segments: an inner metal core that handles thermal management and an outer polymer shell that provides structural protection and aesthetic features. This segmentation allows each material to perform its optimal function without the drawbacks of using it for the entire housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flashlight housing employs a composite structure combining metal core and polymer shell. The metal core (aluminum or aluminum alloy) provides thermal conductivity for heat dissipation, while the polymer shell (acrylonitrile butadiene styrene or similar) provides lightweight structural support and color integration, creating a composite system that leverages the strengths of both materials.

Inventive Principle:

Principle #40Composite materials

2Temperature

If metal alloy housing is used, then thermal conductivity is improved, but color customization capability deteriorates

Engineering Contradiction:

Improvethermal conductivityVSAvoidcolor customization

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The housing is divided into two functional segments: an inner metal core that handles thermal management and an outer polymer shell that provides structural protection and aesthetic features. This segmentation allows each material to perform its optimal function without the drawbacks of using it for the entire housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The polymer shell can be molded with integrated colors and patterns directly into the material, providing durable color customization that does not fade or wear like painted metal surfaces. This allows for high visibility colors, camouflage patterns, and other aesthetic features that would be difficult or expensive to apply to metal.

Inventive Principle:

Principle #32Color changes

3Adaptability or versatility

If polymer housing is used for color customization, then color durability is improved, but thermal conductivity deteriorates

Engineering Contradiction:

Improvecolor customizationVSAvoidthermal conductivity

Core Design Contradiction:

Adaptability or versatilityVSTemperature

Solution Approach 1:

The housing is divided into two functional segments: an inner metal core that handles thermal management and an outer polymer shell that provides structural protection and aesthetic features. This segmentation allows each material to perform its optimal function without the drawbacks of using it for the entire housing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The flashlight housing employs a composite structure combining metal core and polymer shell. The metal core (aluminum or aluminum alloy) provides thermal conductivity for heat dissipation, while the polymer shell (acrylonitrile butadiene styrene or similar) provides lightweight structural support and color integration, creating a composite system that leverages the strengths of both materials.

Inventive Principle:

Principle #40Composite materials

4Adaptability or versatility

If painted metal housing is used for color customization, then color variety is improved, but coating durability deteriorates

Engineering Contradiction:

Improvecolor varietyVSAvoidcoating durability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The polymer shell can be molded with integrated colors and patterns directly into the material, providing durable color customization that does not fade or wear like painted metal surfaces. This allows for high visibility colors, camouflage patterns, and other aesthetic features that would be difficult or expensive to apply to metal.

Inventive Principle:

Principle #32Color changes

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 design effectively dissipates heat from the LED lamp, reduces material weight, and allows for durable color customization, improving the flashlight's performance and longevity.

Implementation Method 1

A heat bridge is thermally coupled to the LED lamp, the metal reflector, and the metal core, thereby conducting heat away from the LED lamp

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10260733B2High power flashlight with polymer shell

Publication Date: 2019.04.16 ARMAMENT SYSTEMS & PROCEDURES INC

AI summary

A high power flashlight with a polymer shell.