Underwater Light With Replaceable LED Module and Insulative Heat Sink
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Solution Overview
Problem
Conventional underwater lights for pools and spas face issues with condensation on the lens, damage to electrical components due to heat, and the need for complex grounding, which limits their installation locations and requires specific approval from Underwriters Laboratories.
Innovation Solution
The design includes a glass lens with a silicon dioxide coating to prevent condensation, a thermally conductive and electrically insulative polymer heat sink, and a replaceable LED module with a potting compound for safe PCB replacement, allowing for installation without specific grounding or approval.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metal heat sink is used for thermal conduction, then heat dissipation is improved, but electrical conductivity increases requiring complex grounding
Solution Approach 1:
The patent employs a polymer heat sink material that combines thermal conductivity with electrical insulation properties. This composite material approach allows the heat sink to effectively dissipate heat from the LED while maintaining electrical isolation, thereby eliminating the need for complex grounding interfaces between the luminaire and niche.
2Reliability
If the luminaire is hermetically sealed, then protection is improved, but LED replacement becomes difficult
Solution Approach 1:
The luminaire is divided into separable modules including a removable lens assembly and a sealed housing containing the electronics. This segmentation allows the lens and LED module to be independently accessed and replaced while maintaining the hermetic seal of the main housing, thus preserving protection while enabling easy LED replacement.
3Ease of manufacture
If conventional materials are used for the lens, then manufacturing is simple, but condensation forms on the interior
Solution Approach 1:
The lens is constructed from a composite material or treated with a specialized coating that provides both optical clarity and thermal insulation properties. This prevents condensation formation on the interior surface by reducing thermal transfer between the exterior and interior of the lens, while still allowing for practical manufacturing processes.
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 solution effectively prevents condensation, ensures safe heat dissipation, and allows for easy replacement of LEDs, enabling the underwater lights to be installed in any pool or spa without the need for specific approval, ensuring safety and flexibility.
Implementation Method 1
The glass layer thermally insulates the underwater light and thereby prevents the formation of condensation caused by a difference between the temperature of the air within the underwater light and the temperature of pool water around the underwater light.
Implementation Method 2
The assembly of the underwater light provides for the dissipation of heat away from the PCB thereby cooling the LEDs and electronic components mounted thereon.
Implementation Method 3
The electrically non-conductive nature of the exterior components of the underwater light (i.e., the lens, the bezel, the mounting flange and the rear housing) permit the underwater light to be installed in any location in a pool or spa without requiring specific approval of Underwriters Laboratories.
Data Source
AI summary
An underwater light having a replaceable light-emitting diode (LED) module and cord assembly is provided. The underwater light includes a lens, a bezel, a screw, a cable attachment assembly, a mounting flange, a rear housing, a fastening assembly, an internal lens, a printed circuit board (PCB) including light-emitting diodes (LEDs) mounted thereon, a heat sink, and an electronics assembly. The assembly of the underwater light provides for the dissipation of heat away from the PCB thereby cooling the LEDs and electronic components mounted thereon. The electrically non-conductive nature of the exterior components of the underwater light permit the underwater light to be installed in any location in a pool or spa. Since the exterior of the underwater light is electrically non-conductive, no specific bonding or grounding of the underwater light is necessary.