Silicone Optical Array Thermal Management in LED Luminaire
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Luminaire assemblies face challenges with thermal cycling, as polycarbonate or acrylic-based optics are expensive and prone to damage, while silicone optics have high expansion coefficients, leading to non-uniform light transmission and structural issues.
Innovation Solution
A silicone optical array with a silicone mat and individually formed silicone optics, secured to a substrate using pegs and a sealing bead, provides a hermetic seal and optical control, while an air vent wireway manages thermal pressure and an optical frame secures the array for uniform light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If polycarbonate or acrylic-based optics are used in an optical array, then expansion and contraction due to thermal cycling is reduced, but manufacturing cost increases and susceptibility to damage over time increases
Solution Approach 1:
The patent changes the material parameter from polycarbonate/acrylic to silicone, and accepts the trade-off of higher thermal expansion by using a larger optic size. This allows the use of cheaper silicone material while maintaining optical performance through compensated design
Solution Approach 2:
The patent transitions from individual small optics to a single large optic configuration, changing the dimensional scale. This allows silicone material to be used effectively despite its high thermal expansion coefficient, as the larger scale enables better control and compensation of expansion effects
2Ease of manufacture
If silicone material is used for optics, then manufacturing cost is reduced, but expansion and contraction due to thermal cycling increases leading to non-uniform light transmission
Solution Approach 1:
The patent uses a single large optic instead of multiple small optics, changing the dimensional scale. This allows the high thermal expansion of silicone to be better controlled and compensated, maintaining uniform light transmission while using the cheaper silicone material
Solution Approach 2:
The patent changes the optical design parameters to accommodate silicone's high thermal expansion coefficient, using a larger optic size that allows for better thermal management and uniform light transmission despite material expansion
3Ease of manufacture
If a single large optic is used to cover multiple LEDs, then manufacturing cost is reduced, but control of the optic shape during thermal cycling becomes more difficult
Solution Approach 1:
The patent uses a single large optic design that, while larger in scale, simplifies the overall structure by eliminating the need for multiple individual optics and their associated mounting complexities. The larger scale allows for integrated design that manages thermal cycling effects more effectively
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 silicone optical array effectively manages thermal expansion, maintains uniform light transmission, reduces costs, and enhances durability, offering improved performance and reduced maintenance for luminaire assemblies.
Implementation Method 1
a single optic that comprises at least a refractor
Implementation Method 2
and also possibly a reflector
Implementation Method 3
silicone material, on the other hand, has a generally high coefficient of linear expansion so its use in optics has been generally limited to a single optic for covering a plurality of LEDs since the size of the silicone optic in this configuration lends itself better for control of its shape during thermal cycling
Data Source
AI summary
A luminaire assembly and a silicone optical array. The luminaire assembly includes a housing, a substrate, and a silicone optical array. The housing defines a light emitting chamber. The substrate has a plurality of light emitting sources, such as light emitting diodes, supported thereby in an array. The substrate defines a peripheral edge. The silicone optical array has a plurality of silicone optics formed in the silicone optical array. The silicone optical array is located so as to cover one side of the substrate and the plurality of light emitting sources. The silicone optical array may further include a silicone mat and a plurality of silicone optics formed in the silicone mat and being arranged in an array corresponding to the array of light emitting sources.