Self-Sealing Refractive Optic for Aircraft Anti-Collision Lighting
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Solution Overview
Problem
Existing aircraft anti-collision lighting systems face issues with short service life due to degradation of electronic components in high-voltage strobe lights, especially in damp environments and high altitudes, and the costly and time-consuming process of replacing xenon, incandescent, or halogen lamps with LEDs.
Innovation Solution
An environmentally-sealed refractive lighting optic using a single LED printed circuit card with a refractive optic element made of liquid silicone rubber or optically-clear low-pressure molded RTV silicone, which provides a self-sealing and mechanical fastener-free solution, allowing the LED components to be retained directly on the card and serving as a form and fit replacement for existing xenon tubes and reflectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If strobe lights with high-voltage DC and xenon gas lamps are used to achieve brilliant flash and high light output, then illumination intensity is improved, but reliability deteriorates due to degradation of electronic components from continuous high-voltage charge and discharge cycles
Solution Approach 1:
The patent replaces the mechanical/electrical strobe system with high-voltage DC and xenon gas lamps with an LED-based system. The LED optic assembly provides the necessary illumination through multiple LED elements arranged in a circular pattern, eliminating the high-voltage charge and discharge cycles that caused component degradation while maintaining brilliant flash capability.
Solution Approach 2:
The patent changes the operating parameters from high-voltage DC to low-voltage DC for the LED elements. This parameter change eliminates the stress of continuous high-voltage cycling on electronic components, thereby improving reliability and service life while still achieving the required illumination intensity for anti-collision lighting.
2Reliability
If LEDs are adopted for aircraft lighting systems to achieve longer life and lower power, then reliability and energy efficiency are improved, but device complexity increases due to the need for custom housing designs that do not fit existing aircraft light module housings
Solution Approach 1:
The patent designs the LED optic assembly to be universally compatible with existing aircraft light module housings. The assembly includes a mounting bracket that can be attached to standard housing structures, and the optic elements are arranged to fit within existing aperture configurations. This universal design allows LEDs to replace traditional lamps without requiring custom housing designs, reducing device complexity while maintaining the reliability and energy efficiency benefits of LED technology.
3Reliability
If refractive optic elements made of liquid silicone rubber or RTV silicone are used to environmentally seal LED components, then reliability is improved by protecting against damp environments, but manufacturing precision requirements increase due to the need for self-sealing without mechanical fasteners
Solution Approach 1:
The patent employs refractive optic elements made of liquid silicone rubber or RTV silicone that automatically seal around the LED components through their inherent material properties. The silicone material flows and conforms to the LED housing contours, creating an environmental seal without requiring mechanical fasteners or precise alignment features. This self-sealing mechanism reduces manufacturing precision requirements while improving reliability by protecting against damp environments.
Solution Approach 2:
The patent uses composite material construction where refractive optic elements are made from silicone-based materials that combine optical clarity with sealing properties. The liquid silicone rubber or RTV silicone provides both the refractive function for light distribution and the sealing function for environmental protection, eliminating the need for separate sealing components and reducing manufacturing complexity.
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 configuration significantly reduces the size, weight, and power consumption of aircraft anti-collision lighting systems while increasing their service life by eliminating the need for mechanical fasteners and providing a robust environmental seal.
Implementation Method 1
a single, refractive optic element retained directly to the LED printed circuit card in a self-sealing manner
Data Source
AI summary
An environmentally-sealed refractive lighting optic includes a single light-emitting diode (LED) printed circuit card that includes a plurality of LED components and a single, refractive optic element retained directly to the LED printed circuit card in a self-sealing manner without mechanical fasteners. The refractive optic element is configured to environmentally seal the LED components on the LED printed circuit card. Further, the refractive optic element may include a liquid silicone rubber material or an optically-clear low-pressure molded room temperature vulcanizing (RTV) silicone material.