Segmented Reflector Arrays for LED Floodlight Thermal Management

Solution Overview

Problem

LED floodlights face challenges in meeting various standards and regulations, such as IP66 and temperature ratings, while maintaining durability and efficient light distribution in harsh environments, and existing reflector designs may not effectively manage thermal and electrical paths to ensure safe and reliable operation.

Innovation Solution

The reflector array design incorporates multiple reflector sections with reflective materials and neutral sections made of non-reflective, electrically non-conductive materials, which are strategically positioned to receive light sources and manage thermal and electrical paths, allowing for closer spacing of light sources and reduced voltage potential, while maintaining compliance with standards like IP66 and ensuring secure thermal paths.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional reflector designs are used, then light distribution may be achieved, but thermal and electrical paths are not effectively managed, compromising safety and reliability

Engineering Contradiction:

Improveoperational safetyVSAvoidreflector design complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The reflector array is divided into multiple reflector sections, each with its own aperture and reflector wall. This segmentation allows independent management of thermal and electrical paths for each section while maintaining overall light distribution functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the reflector array have different properties: reflector sections have reflective surfaces for light redirection, while neutral sections have non-reflective, electrically non-conductive materials for thermal management. This local differentiation enables simultaneous optimization of light distribution and thermal safety.

Inventive Principle:

Principle #3Local quality

2Area of stationary object

If light sources are spaced farther apart, then thermal management may be improved, but the lighting fixture requires larger area and the light distribution becomes less uniform

Engineering Contradiction:

Improvelighting fixture areaVSAvoidthermal management

Core Design Contradiction:

Area of stationary objectVSStability of the object's composition

Solution Approach 1:

The reflector array is divided into multiple reflector sections, each with its own aperture and reflector wall. This segmentation allows independent management of thermal and electrical paths for each section while maintaining overall light distribution functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the reflector array have different properties: reflector sections have reflective surfaces for light redirection, while neutral sections have non-reflective, electrically non-conductive materials for thermal management. This local differentiation enables simultaneous optimization of light distribution and thermal safety.

Inventive Principle:

Principle #3Local quality

3Illumination intensity

If more reflector sections are added to improve light distribution, then lighting coverage increases, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improvelight distribution uniformityVSAvoidmanufacturing simplicity

Core Design Contradiction:

Illumination intensityVSEase of manufacture

Solution Approach 1:

The reflector array is divided into multiple reflector sections, each with its own aperture and reflector wall. This segmentation allows independent management of thermal and electrical paths for each section while maintaining overall light distribution functionality.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each reflector section is designed as a modular unit that performs multiple functions: light reflection, thermal management, and electrical isolation. This multi-functionality reduces the need for separate components and simplifies manufacturing despite the increased number of sections.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 enables LED floodlights to meet stringent standards, maintain durability, and achieve uniform light distribution, allowing for closer light source spacing and secure thermal paths, thus enhancing operational safety and efficiency.

Implementation Method 1

each reflector has at least one reflector wall that has a reflective material

Methodology Applied

Scientific EffectReflection: Reflection

Data Source

PatentUS9322528B2Reflector arrays for lighting devices

Publication Date: 2016.04.26 EATON INTELLIGENT POWER LTD

AI summary

A reflector array for a lighting fixture can include at least one reflector section and at least one neutral section. The at least one reflector section can include a number of reflectors, where each reflector has at least one reflector wall having a reflective material and an aperture that traverses the at least one reflector wall, where each aperture is configured to receive a light source disposed on a mounting surface of the lighting fixture. The at least one neutral section can include an electrically non-conductive material, where the at least one neutral section is disposed adjacent to the at least one reflector section.