Integrated Signal Light Head with Remote Power Supply

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing signal light heads require the entire LED-based module to be replaced when the power supply fails, leading to wastage of functional components and inefficiencies in maintenance and cost.

Innovation Solution

An integrated signal light head design with a remotely located power supply compartment that allows for plug-and-play replacement of power supplies, eliminating the need to remove the entire module and reducing material waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If the power source is located inside the LED-based light module, then the entire module can be replaced as a single unit, but the rest of the module including LEDs, housing, wiring, connectors, and lenses must be wasted when the power source fails

Engineering Contradiction:

Improveease of replacementVSAvoidmaterial waste

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent divides the signal light head into separate functional modules: the LED light module and the power source compartment. This segmentation allows the power source to be replaced independently without discarding the functional LED components, housing, wiring, connectors, and lenses. The separate compartments enable selective replacement of only the failed component.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The power source is extracted from the LED-based light module and placed in a separate compartment. This extraction allows the power source to be removed and replaced independently when it fails, while the LED module and other components remain in place and continue to function, thereby eliminating material waste.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of repair

If the entire LED-based module is replaced when the power supply fails, then the replacement process is simple, but the maintenance cost and material usage increase

Engineering Contradiction:

Improveease of replacementVSAvoidmaintenance time

Core Design Contradiction:

Ease of repairVSLoss of time

Solution Approach 1:

By segmenting the signal light head into separate modules (LED module and power source compartment), the patent enables targeted replacement of only the failed power source rather than the entire assembly. This reduces maintenance time and resource allocation while maintaining ease of replacement through modular design.

Inventive Principle:

Principle #1Segmentation

3Volume of moving object

If the power source is integrated with the LED module, then the structure is compact, but heat dissipation is reduced and the size and weight of the signal light head increase

Engineering Contradiction:

Improvesize of signal light headVSAvoidheat dissipation

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The patent separates the power source from the LED module into distinct compartments. This segmentation improves heat dissipation by allowing each component to be thermally managed independently, with the power source generating heat isolated from the sensitive LED components. The separated structure optimizes thermal performance while maintaining a compact overall design.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS9068704B2Integrated signal light head

Publication Date: 2015.06.30 DIALIGHT CORP

AI summary

The present disclosure relates generally to an integrated signal light head. In one embodiment, the integrated signal light head includes a molded housing for holding at least one light emitting diode (LED) light source and a power supply compartment coupled to the molded housing. As a result, a power supply may be remotely located and independent of the at least one LED light source.