Removable Liquid-Cooled LED Module for Production Lamp Color Consistency
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Solution Overview
Problem
Traditional production lamps using sodium bulbs require color gels for color adjustment, suffer from color temperature mismatches with LED bulbs, and face issues with LED fading and color drift over time, making it difficult to maintain consistent lighting.
Innovation Solution
A production lamp design featuring a removable, liquid-cooled LED lighting module with a Fresnel lens for focusable output, capable of producing virtually any color, and integrated with a trolley system for easy replacement and connection, allowing for simultaneous electrical, mechanical, and fluid connections with a single motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If LED bulbs are used to replace sodium bulbs, then energy efficiency is improved, but color temperature consistency and color accuracy deteriorate
Solution Approach 1:
The lighting system is divided into multiple independent LED modules, each containing LEDs of different color temperatures (warm white, cool white, daylight). This segmentation allows selective combination of modules to achieve desired color temperatures while maintaining energy efficiency of individual LED components.
Solution Approach 2:
The system enables dynamic adjustment of color temperature parameters by varying the intensity ratios of LEDs with different color temperatures. Controllers adjust the output of each LED type to maintain consistent color appearance over time, compensating for LED aging and drift.
2Adaptability or versatility
If color gels are used to adjust LED color output, then color versatility is improved, but light intensity and system complexity deteriorate
Solution Approach 1:
The invention extracts and eliminates the need for color gels by directly generating desired colors through LED combinations. The system uses multiple LED types with different color temperatures to produce various color outputs without requiring additional filtering layers, thereby removing the light intensity loss associated with gel filters.
Solution Approach 2:
The LED modules are designed to perform multiple functions: they can generate different color temperatures, adjust intensity levels, and replace both the light source and color filtering functions that were previously separate components (sodium bulb + gel combination).
3Temperature
If cooling systems are integrated into the lamp housing, then heat dissipation is improved, but LED replacement difficulty and system complexity deteriorate
Solution Approach 1:
The cooling system is segmented and integrated directly into each removable LED module rather than being part of the fixed housing. Each module contains its own heat sink and cooling channels, allowing the module to be replaced as a complete unit without disrupting the cooling system or requiring complex disassembly.
Solution Approach 2:
The cooling function is merged with the LED module structure. The heat sink and cooling channels are combined with the LED mounting structure, creating an integrated thermal management solution that moves with the module during replacement.
4Ease of repair
If LED modules are made removable and replaceable, then maintenance ease is improved, but connection reliability and structural complexity deteriorate
Solution Approach 1:
The module connection structure incorporates pre-configured alignment features, guide pins, and self-latching mechanisms that automatically ensure proper positioning and secure connection during insertion. This preliminary configuration of connection elements eliminates the need for precise manual alignment and ensures reliable electrical and mechanical connections.
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 flexible, efficient, and long-lasting lighting solution by eliminating the need for color gels, minimizing color temperature discrepancies, and reducing heat-related issues, thereby extending the lamp's usable life and ensuring consistent color and intensity output.
Implementation Method 1
A production lamp design featuring a removable, liquid-cooled LED lighting module with a Fresnel lens for focusable output
Implementation Method 2
A production lamp design featuring a removable, liquid-cooled LED lighting module
Data Source
AI summary
A production lamp is provided with a removeable lighting module. The removeable lighting module includes an array of LEDs mounted to a plate. A cooling module circulates fluid through a plate behind the array of LEDs to dissipate heat. A driver module generates variable signals to power each of the LEDs in the array to create myriad color output of highly variable intensity. Dripless fluid connectors mounted to the plate connect the cooling module in fluid communication with the plate. Movable pins mounted in the plate electrically connect the LED array to the driver module. Finally, a tool-less actuator mounted in the removeable lighting module disconnects both the dripless connectors and the pins for removal and replacement of the LED module.