Reflector Sealing Assembly for Weatherproof LED Lighting
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Solution Overview
Problem
Current exterior lighting assemblies face challenges in providing a reliable weatherproof seal between the housing and the transparent cover or lens, particularly for LED-based systems, as existing solutions require modifications to the housing or lens to accommodate seals, which can be costly and complex.
Innovation Solution
A lighting assembly design featuring a reflector with continuous channels on both inner and outer surfaces to house seal members, allowing for a weatherproof seal without modifying the housing or lens, using a molded plastic reflector with a central opening and surrounding channels to integrate the seal members for a one-piece solution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a seal member is added to form a weatherproof seal between the housing and transparent cover, then the weatherproof protection is improved, but the device complexity increases due to additional components and modifications to housing or lens
Solution Approach 1:
The seal member is integrated into the reflector assembly, combining the sealing function with the existing reflector structure. The reflector includes a first seal member on its inner surface and a second seal member on its outer surface, eliminating the need for separate sealing components and modifications to the housing or lens.
Solution Approach 2:
The reflector serves multiple functions: it reflects light outwardly from the light source, provides structural support for the seal members, and creates the weatherproof seal between the housing and transparent cover. This multi-functionality reduces the overall number of components needed in the lighting assembly.
2Ease of manufacture
If seal members are integrated into the reflector, then the manufacturing cost is reduced by eliminating modifications to housing or lens, but the manufacturing precision requirements increase for the reflector
Solution Approach 1:
The seal members are formed as integral parts of the reflector structure, which can be manufactured as a single molded component. This integration eliminates the need for separate sealing components and the complex modifications to housing or lens that would otherwise be required, reducing overall manufacturing complexity despite the added precision requirements for the reflector itself.
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 provides a cost-effective, easy-to-assemble weatherproof enclosure for LED lighting assemblies, ensuring protection from water and dirt without additional gaskets or modifications, while maintaining heat dissipation and efficient light reflection.
Implementation Method 1
the reflector has an inner face for reflecting light outwardly from the light source
Implementation Method 2
a first seal member on an inner surface for forming a seal between the reflector and the surface of the housing and a second seal member on the outer surface for forming a seal between the reflector and the light transmitting cover
Data Source
AI summary
A lighting assembly is provided having a housing supporting a lighting source such as a plurality of LEDs, a reflector having a central opening for the light source, a light transmitting cover and a frame attached to the housing to couple the frame and the light transmitting cover to the housing. The reflector has an outer perimeter with a channel formed in the top face and the bottom face for a continuous seal member. The frame is coupled to the housing to capture the frame and the light transmitting cover between the frame and the housing so that the seal members form a weatherproof seal between the light transmitting cover and the frame and between the frame and the face of the housing.