RU2476764C1 - Protected high output led spotlight - Google Patents

Abstract

FIELD: electrical engineering.

SUBSTANCE: spotlight contains a concave body in the shape of a conic or pyramidal frustrum made of a heat conductive material, finned on the rear side and having a round, oval or rectangular outlet hole with a protective glass, with high output /1-5 W/ LEDs assembled inside, as well as a chamber with a power supply and s control unit. Arranged on the body inner side walls is a cascade of steps, coaxially positioned and matching the shape of the outlet hole; mounted on the steps in a thermal contact are frames made of a thermally conductive material forming the fins of the conductive heat removal inner radiator; assembled on such fins in thermal contact are LED modules, lines of LEDs or individual LEDs with optic axes simultaneously displaced in sagittal and meridional planes and mutually parallel. mounted on the LEDs may be secondary optic elements such as menses generating a uniform, narrower irradiation flux. The frames may have external flanging made of L-shaped profile and are mechanically clamped to the walls of each step simultaneously with the boards of LED modules or lines with an aluminium foundation.

EFFECT: extension of the spotlight functional capabilities through provision for the irradiation type control function.

6 cl, 6 dwg

Description

The present invention relates to lighting engineering, in particular to protected floodlight illuminators / spotlights, headlights / or luminaires with high-power LEDs, including explosion-proof performance, working with cooling radiators in the infrared and visible spectral range, as well as with the possibility of switching the type of radiation.

Illuminators are intended for illumination of distant objects in the visible and / or near-infrared spectral ranges and during operation they are mainly installed on armored vehicles, helicopters, airplanes, for example, in explosion-proof versions to illuminate the refueling procedure in the air, as well as for use in units MOE.

At the same time, illuminators can be used for security, architectural lighting and other applications.

Known multi-purpose combined searchlight for armored vehicles [1], using a traditional light source / gas discharge lamp or incandescent lamp / in combination with LED modules with secondary optics elements mounted on cooling radiators, including with conductive heat transfer to the walls of the spotlight.

The disadvantages of the analogue include increased dimensions due to the use of a paraboloid reflector for the formation of a narrow beam of radiation and complex means of converting radiation in the form of an IR filter that absorbs more than 40% of the radiation of the light source, as well as the complex design of the power source and control of the searchlight.

A well-known protected light device is a floodlight type illuminator [2] with an optical module based on relatively powerful LEDs working with cooling radiators, on the basis of which explosion-proof headlights FR-VS "Ecoton-3" and FS-VSM "Ecoton-5" [3] are developed .

The lighter contains a protected concave housing made of heat-conducting material with an outlet, covered by a mandrel with a protective glass and mounted inside the cooling radiator with an optical module on LEDs with parallel optical axes, coupled to the secondary optics element with an optical array of square cells with Fresnel disk lenses with a direct carrier layer .

The disadvantages of the prototype are due to the fact that the coverage angle of each lens of the grating does not exceed 30 °, which makes it difficult to use more powerful modern LEDs with several crystals and radiation scattering angles of 2θ≃90-140 °.

In addition, the problem of cooling the illuminator with such LEDs with a power of 2-3 W or more has not been solved.

The aim of the invention is the creation of a protected illuminator with high-power LEDs with improved thermophysical and optical characteristics, providing a high concentration of light radiation on the illuminated objects with reduced dimensions of the outlet, with enhanced functionality.

This goal is achieved by the fact that in a protected illuminator with high-power LEDs containing a concave housing made of heat-conducting material, at least partially finned on the back, with a round, oval or rectangular outlet, covered with a protective glass or lens optical element, assembled inside on cooling radiator with LEDs with optical axes facing the outlet and connected to a power source with a control unit installed in a protected camera on the inside a cascade of steps made coaxially arranged and repeating the shape of the outlet, on which the frames of heat-conducting material are installed in the thermal contact, forming the fins of the internal heat sink of the conductive heat sink, on the side of the outlet facing the outlet, the LED modules are mounted on the side of the heat contact; LEDs or individual LEDs with optical axes offset in the sagittal and meridional planes parallel to each other.

The goal is achieved by the fact that on the steps of the cascade of the casing, integral or composite shaped frames with LED modules, rulers with LEDs or individual LEDs with secondary optics elements / lenses / mounted on them, forming a single beam of illuminator are assembled in thermal contact.

Achieving the goal is also facilitated by the fact that the side walls of the case have the shape of the walls of a truncated cone or faces of a regular truncated pyramid with cooling fins on the outer surface and a cascade of equally spaced steps on the inner walls, and the small base of the truncated cone or pyramid is paired with a protected camera with a power source with a control unit made in the form of a monoblock, filled with a heat-conducting electrical insulating compound.

The goal is also achieved by the fact that solid or composite frames with LED modules, arrays or individual LEDs have an L-shaped profile and are mechanically pressed on the steps of the cascade of the housing in thermal contact to the front and side of each step using a screw mount or a heat-conducting adhesive compound.

The task is also solved by the fact that the LED modules or lines with LEDs installed in the protected case are made on boards with an aluminum base with closed mounting of LEDs, the boards being connected to each other and to a power source with an explosion-proof hermophrodite connector control unit, and a camera for a power source with a control unit and means for connecting the supply network is made explosion-proof with a threaded cable entry and an explosion channel made of a protected thread.

In one embodiment, the goal is also achieved by the fact that the illuminator uses LED modules or arrays with visible LEDs and near-infrared radiation, mounted on the cascade of the housing or mounted directly in the indicated modules or arrays with alternating types of radiation and independently connected to the source power supply with a control unit with the possibility of separate operation with the selected type of radiation.

Preferred embodiments of illuminators with high-power LEDs according to the invention are shown in the drawings.

Figure 1. Protected illuminator from cascades of ring steps and curly frames with LEDs and lenses in a truncated cone-shaped case, side view, partially in section.

Figure 2. The same as in figure 1, a front view, without a mandrel with a protective glass.

Figure 3. Explosion-proof illuminator with a cascade of steps and rectangular shaped frames with LEDs and lenses in the body in the form of a correctly truncated pyramid, side view, partially in section.

Figure 4. The same as in figure 3, a front view, without a mandrel with a protective glass.

Figa, b, s. A fragment of the mechanical fastening of the frame with LEDs on the step of the cascade of the housing.

6. Block diagram of the connection of the illuminator to a power source with a radiation type control unit.

Shown in figures 1 and 2, the first version of the protected illuminator with high-power LEDs contains a concave housing 1 made of heat-conducting material, mainly based on aluminum alloys with a round outlet, covered with thermally toughened silicate protective glass 2 or made of optically transparent high-impact polycarbonate, mounted hermetically in a mandrel 3, connected to the housing with screws through the seal 4.

On the back side of the housing 1, fins 5 for cooling the illuminator are made, and on the inner side walls of the housing there is a cascade of steps 6 in the form of ring steps of different diameters coaxially arranged and repeating the shape of the outlet opening, parallel and equidistant to each other. In this case, the walls of the housing have the shape of the walls of a truncated circular cone 7, the large base of which is the outlet of the illuminator.

On each annular step 6 of the cascade of the casing annular solid or composite frames 8 of heat-conducting material are installed in thermal contact, mainly curly frames with semicircular cuts / cm. also. figb /, forming the fins of the internal radiator of the conductive heat sink, on the side facing the outlet, the LED modules 9, annular bars with LEDs 10, or individual LEDs with parallel optical axes are mounted in thermal contact.

The inclination of the generators of the truncated cone - the walls of the housing 7 is chosen so that the flat angle of the solution of the specified cone is not less than double / full / angle of radiation scattering of the visible LEDs and / or IR radiation to minimize losses during operation of the illuminator without the use of secondary optics.

In one embodiment of the illuminator, individual elements of secondary optics / lenses / 11 are installed on each LED 10 of the module or annular line, forming a single radiation beam with a smaller scattering angle, i.e. converting the radiation of LEDs with scattering angles 2θ≃90-140 ° into narrower beams, mainly in the range from 3 to 60 °.

LEDs 10 with lenses 11 installed in modules, annular arrays or directly on the cascade of the casing with parallel optical axes are maximally close to each other in the plane of the outlet of the illuminator without deterioration of its thermal parameters due to the displacement of these supporting elements, and therefore the displacement of the optical axes of the LEDs in the sagittal and meridional planes corresponding to the positions of the annular frames on the axially displaced steps of the cascade of the housing, and the execution of these frames curly with Zami close the diameter of each lens.

LED modules or ring rulers with LEDs 10 are made on printed circuit boards with an aluminum base or on heat-conducting ceramic boards, for example, based on rubalite / Al ₂ O ₃ / or aluminite / AN / with intermetallic fastening of the LED crystal, which provides high conductive heat dissipation to the module board or rulers.

In turn, the thermal contact of the module 9 or line with LEDs 10 with a flat front part of the figured frame 8 and / or step 6 of the cascade of the housing / cm figure 1 and 5 / is achieved by compressing them with screws 12. It is also possible to use for mounting modules or lines with LEDs on the frame and / or on the steps of the cascade of the casing of the heat-conducting adhesive compound.

Made in the form of a truncated cone, the housing 1 of the illuminator with a small base / rear / is connected to a protected camera 13 with a cable entry 14 of the power supply network, in which a power supply 15 with a control unit for LEDs operating modes is installed.

Modules or lines with LEDs are connected to each other and to a power supply with a control unit for connectors 16 or screwless terminal blocks.

The power source 15 with the control unit can be made in the form of a monoblock, filled with a ceramic-polymer heat-conducting dielectric compound.

On the back of the housing 1 installed lyre 17 for mounting the illuminator on the object.

Figures 3, 4 and 5a, b, c show a second variant of a protected illuminator with high-power LEDs in explosion-proof design, intended, for example, to illuminate the operation of refueling aircraft with air in air.

The illuminator contains a partially ribbed, long concave body 18 of heat-conducting material with a rectangular outlet, covered by a protective glass 19, sealed in a mandrel 20, tightened by bolts through a seal 21 with the housing flange.

The side walls of the housing 18 are in the form of faces of a regular truncated quadrangular pyramid with cooling ribs 22 on the outer surface, the large base of which forms a rectangular outlet of the illuminator.

The inner side walls of the housing 18 are made in the form of a cascade of extended, equally spaced steps 23, mainly of rectangular cross section, coaxially located in the housing 18 and having a rectangular shape similar to the outlet of the illuminator.

On each step of the cascade of the casing, solid or composite rectangular frames 24 are installed, which can be made curly, i.e. with semicircular cuts / cm. figb /. The frames 24 are made of heat-conducting material with a width exceeding the width of the step 23, have a predominantly L-shaped profile and are assembled in thermal contact with the front and side of the step / cm. figa, b / using screw 25 fastening or heat-conducting adhesive compound.

Thus, the frames 24 installed on the steps 23 of the cascade of the casing of the frame form the fins of the internal radiator of the conductive heat sink to cool the LED modules or extended lines 26 mounted on them in thermal contact with LEDs 27 with O-O parallel optical axes.

To increase the concentration of radiation in the outlet of the illuminator, the LEDs 27 are as close as possible to each other, with a parallel shift of the O-O optical axes in the meridional plane relative to the LEDs located on an adjacent parallel, axially offset step corresponding to another sagittal plane that cuts through the illuminator body perpendicular to its optical ZZ axis.

A truncated pyramid-shaped case I8 has a small base coupled to an extended chamber 28, in which a power supply 29 is installed with a control unit made in the form of a monoblock filled with a heat-conducting ceramic-polymer compound, with a built-in WAGO terminal block or an explosion-proof Tuc poke-in connector of Tus type Electronics / Germany / with silicone gel filling of the contact system [4].

The chamber 28 is sealed by a cover 30 installed through a bolt seal, in which a cable entry 32 is made along a protected thread 31 for connecting the supply network to the illuminator.

Protected by an annular seal 33, the thread of the cable entry 32 forms an explosion channel 31, providing explosion protection of the chamber 28.

Transit cable entries made for group operation of illuminators without using junction boxes and circuits, for example, in architectural or general industrial lighting can be made on the side walls of the chamber 28 / in FIG. not shown.

LED modules or long lines 26 with LEDs are made on boards with an aluminum base with a secure installation of means for connecting LEDs 27 to each other. In this case, the LED modules or rulers with LEDs connect the aforementioned explosion-proof gas-tight connectors to each other, and with a power supply with a protected cable control unit sealed in the hole of the nipple connecting the illuminator to the flameproof chamber 28 / in FIG. not shown.

To form a given shape, beam width and luminous intensity in selected directions, each LED of a module or ruler is paired with an element of secondary optics, i.e. lenses 34 are mounted on the LEDs 27, forming a single beam of light from the illuminator with the transformation of its round-symmetrical shape with a total scattering angle of 2θ≃115 °, for example, for CREE XP-E LEDs [5] into a beam of radiation with 2θ≃6 ° when using a lens type LEDIL LXP-RSFA 10661, for example, for vehicles, or converting a round-symmetric radiation beam, XR-E series LEDs with 2θ≃120 ° into an oval beam with 2θ≃41 ° × 10 ° when using CAERCLO's 10203 Elliptical lens for aircraft illuminators.

These lenses have dimensions of ⌀21.6 × 14.6 mm and ⌀21.5 × 12.5 mm, respectively, and are interfaced with LED modules or rulers with a glue-based base or special clamp holders with the maximum possible approximation to each other when mounted in the housing illuminator, in particular, due to the implementation of 24 curly frames with semicircular cuts / cm. 4 and 5 / in which they are located.

In one embodiment, to expand the functionality of the protected illuminator, it uses 1–5 W visible-light emitting diodes of the aforementioned series installed directly on the cascade of the casing or mounted directly in modules or lines, as well as the XP-G series in combination with near-IR LEDs -radiations of similar power in the spectral range 800–950 nm, for example, with HPLigting series LEDs of the HPL-Н77FjIBA / Taiwan / type [6], generating radiation with a power of 140-150 mW at a scattering angle of 2θ≃120 °, at orye can be installed the same lens as on LEDs XP-E and XP-G Series of white light.

LEDs are installed in modules or rulers with an alternation of the type of study / visible - IR / and independently connect / cm. 6 / to a power source with a control unit with the possibility of separate operation with the selected type of radiation using a switch.

The indicated operating modes of the illuminator are used during its operation, for example, at objects of armored vehicles when night vision devices fail.

Thus, the developed versions of a protected illuminator with high-power LEDs have improved thermophysical and optical characteristics, provide a high concentration of optical radiation in illuminated objects with a 1.5-2 times reduced outlet size due to a denser layout and increased power of the applied LEDs without compromising thermal parameters.

The functionality of the illuminator has also been expanded due to its explosion-proof performance and providing the function of controlling the type of radiation.

Literature

1. Sysun V.V. Combined floodlight. Pat. RF №2245488. Kl. F21S 8/00, publ. January 27, 2005, Bull. Number 3.

2. Kogan L.M. and others. LED light fixture. Pat. RF №2202731. Kl. F21V 5/00, publ. 04/20/2003, bull. No. 11.

3.Basov Yu.G. and other Special lighting Linek, "IC BSU", 2008, pp. 379-380.

4. Slobodenyuk A. Overview of Tuso Electronics connectors for LED technology. J. Semiconductor lighting technology, 2010, No. 3, p.21.

5. Catalog of the company PROSOFT. Powerful LEDs and secondary optics. 2009. p. 9, 52.

6. Catalog of the company "Neon". Electronic components. SPb., 2010, p. 9.

Claims (6)

1. Protected illuminator with high-power LEDs, containing a concave housing made of heat-conducting material, at least partially finned on the back, with a round, oval or rectangular outlet, covered with a protective glass or lens optical element, with LEDs assembled inside on the cooling radiator with optical axes facing the outlet and connected to a power source with a control unit installed in a protected camera, characterized in that on the inner side walls of the casing there is a cascade of steps, coaxially arranged and repeating the shape of the outlet, on which the frames of heat-conducting material are installed in the thermal contact, forming the fins of the internal heat sink of the conductive heat sink, on the sides of the radiator facing the outlet, LED modules, LED strips or separate LEDs are mounted LEDs with optical axes offset in the sagittal and meridional planes parallel to each other. 2. The protected illuminator according to claim 1, characterized in that on the steps of the cascade of the housing, integral or composite curly frames with LED modules, rulers with LEDs or separate LEDs with secondary optics elements (lenses) mounted on them are assembled in thermal contact, forming a single beam radiation illuminator. 3. The protected illuminator according to claim 1, characterized in that the side walls of the housing have the shape of the walls of a truncated cone or faces of a regular truncated pyramid with cooling fins on the outer surface and a cascade of equally spaced steps on the inner walls, the small base of the truncated cone or pyramid mating with a protected camera with a power source installed in it with a control unit made in the form of a monoblock filled with a heat-conducting electrical insulating compound. 4. The protected illuminator according to claim 1, characterized in that the integral or composite frames with LED modules, rulers with LEDs or individual LEDs have an L-shaped profile and are mechanically pressed on the steps of the cascade of the housing in thermal contact to the front and side of each step when using a screw mount or a heat-conducting adhesive compound. 5. The protected illuminator according to claim 1, characterized in that the LED modules or lines with LEDs installed in the protected case are made on boards with an aluminum base with a closed mounting of LEDs, the boards being connected to each other and to a power source with an explosion-proof hermaphrodite connector control unit, and the chamber for the power source with the control unit to the means for connecting the supply network is made flameproof with a threaded cable entry and an explosion channel through a protected thread. 6. The protected illuminator according to claim 1, characterized in that LED modules or arrays with visible light emitting diodes and near infrared radiation are used, mounted on the housing cascade, or mounted in the indicated arrays or arrays with alternating types of radiation, and independently connected to a power source with a control unit with the possibility of separate operation with the selected type of radiation.

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