• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Abstract: A floodlight comprising an enclosure adapted to contain a plurality of banks of LEDs, at least one driver for the 5 LEDs positioned remote from the LEDs, the enclosure including a heat sink and air vents positioned between the banks of LEDs and the driver wherein heat generated by the LEDs and driver draws air into the enclosure past the heat sink to exit through the air vents to cool the floodlight. 4238966_1 (GHMatters) P91385.AU.1 10/04/13
    公开号:AU2013203425A1
    申请号:U2013203425
    申请日:2013-04-10
    公开日:2014-04-17
    发明作者:Anthony Franklin；Larry Liang；Paul Lindsay；Ken Sturgeon；Andrew Trezise
    申请人:Hella Australia Pty Ltd；
    IPC主号:F21V23-00
    专利说明:
    - 1 A FLOODLIGHT Introduction This invention relates to floodlights and especially 5 though not exclusively floodlights for use in the mining industry. Background of the Invention The mining industry demands floodlights with ever 10 increasing light outputs. These days many floodlights incorporate light emitting diodes (LEDs) and operate on a comparatively low DC voltage, such as 24 volts. A problem of using multiple series of LEDs is the heat that is generated from the LEDs, LEDs have to operate between 15 temperatures of -40 0 C and 70 0 C. The LEDs are expected to have an operating life of approximately 50,000 hours. The operating life of an LED is substantially reduced in high temperature environments and thus the thermal management of a light incorporating LEDs is critical. The light also 20 needs to have the desired optics in terms of direction concentration, and uniformity of the light. LEDs require electronic drivers which tend to produce electronic noise, which can be detrimental to other electronic equipment operating in the vicinity. There is also a need for 25 floodlights of this kind to be rugged and able to withstand extremes of temperature, shock and corrosion. It is these issues that have brought about the present invention. 30 Summary of the Invention In accordance with one aspect of the present invention there is provided a floodlight comprising an enclosure adapted to contain a plurality of banks of LEDs, 35 at least one driver for the LEDs positioned remote from the LEDs, the enclosure including a heat sink and air vents positioned between the banks of LEDs and the driver 4238966_1 (GHMatters) P91385.AU.1 10/04/13 - 2 wherein heat generated by the LEDs and driver draws air into the enclosure past the heat sink to exit through the air vents to cool the floodlight. 5 Preferably each bank of LEDs is position beneath a TIR lens and an outer lens covers the TIR lens. The heat sink may comprise a series of spaced fins on the rear of the enclosure. In a preferred embodiment the 10 enclosure has brackets on either side pivotally secured to an arm structure adapted to be located on the end of a post or mast. Description of the Drawings 15 An embodiment of the present invention will now be described by way of example only with reference to the accompanying drawings in which: Figure 1 is a perspective view of a floodlight, 20 Figure 2 is a rear elevational view of the floodlight, Figure 3 is a side elevational view of the floodlight, Figure 4 is a plan view of the front of the 25 floodlight with some components removed, Figure 5 is a plan view of the front of the floodlight illustrating a shield covering circuit boards, Figure 6 is a schematic illustration of a lens arrangement of the floodlight, 30 Figure 7 is a perspective view of a TIR inner lens, Figure 8 is a partial section through the floodlight illustrating the inner and outer lenses, Figure 9a is a cross sectional view of the floodlight, 35 Figure 9b is an enlargement of the cross section taken within the circle shown in Figure 9a, Figure 10 is an enlarged plan view of the floodlight 4238966_1 (GHMatters) P91385.AU.1 10/04/13 - 3 illustrating one corner of the light, Figures 11a and lb are respectively side and plan views of the floodlight illustrating airflow through the floodlight, 5 Figure 12 is a schematic view of the floodlight taken from the side showing airflow, and Figure 13 is a cross sectional view of part of one side of the floodlight showing mounting of the floodlight to a support bracket. 10 Description of an Embodiment The floodlight of an embodiment of the present invention provides 20,000 lumens of light on a 24 volt DC supply using approximately 280 watts. The floodlight has 15 an operating life of 50,000 hours and is designed to operate successfully in a mining environment in temperatures of 40 0 C to 70 0 C. The light is approximately 10kg in weight yet sufficiently robust to withstand the shock loads and other physical extremes that are common 20 place in mining environments. The floodlight 10 shown in the accompanying drawings, essentially comprises a housing 11 moulded in aluminium to support banks of LEDs and drivers for the LEDs. The LEDs 25 including appropriate optics to control the output of the floodlight. Either side of the housing 11 is secured to a support structure which is in turn attached to a mast or post. 30 As shown in Figures 1 to 3, the housing 11 comprises a substantially rectangular enclosure 12 defined by an upturned skirt 13 with slightly rounded corners. The front 14 of the housing defines the open enclosure 12 and the rear face 15 of the housing is provided with a series 35 of parallel spaced fins 16 that operate as a heat sink to cool the assembly in use. 4238966_1 (GHMatters) P91385.AU.1 10/04/13 - 4 As shown in Figure 2 elongate brackets 20, 21 are bolted to each side of the rear 15 of the housing 11. Each brackets 20, 21 is in turn screwed to an arm 22, 23 that is pivotally screwed to the bracket 20, 21 via a circular 5 plate 24 at one end of the arm 22, 23. The lower end 25 of each arm 22, 23 merges with a mount 26 that extends along one edge of the housing 11. The mount 26 can be attached to a mast or post (not shown). 10 As shown in Figures 4 to 5, the enclosure 12 defined by the housing 11 supports four banks 30, 31, 32, 33 of LEDs 50 spaced in pairs along the longer sides of the enclosure 12. Each bank 30, 31, 32 or 33 of LEDs comprises a circuit board 38 supporting fourteen LEDs 39 in two spaced 15 rows. A plug 45 at one end of each board 38 supplies power to the LEDs 50. Each board 38 is held to the housing by four spaced screws 46. The space between the banks of LEDs is partially filled by a pair of drivers 34, 35 in the form of printed circuit boards that are 20 positioned centrally of the space with open heat dissipation channels 40, 41 running in a parallel spaced apart manner between the banks of LEDs 30 to 33 and the drivers 34, 35. The shorter sides of the rectangle enclosure 12 incorporates the wiring, plug and socket 25 arrangements between the drivers and the support boards for the LEDs. The drivers 34, 35 include electrical componentry to step down and rectify the input power to 24 volts DC. 30 As shown in Figure 5 a metal shield 47 that is an EMC shield is positioned to cover the drivers 34, 35. As shown in Figure 1 the spaces at either side of the enclosure which locates the wiring and the shield are covered by an H shaped outer cover 51. A single outer 35 lens 52, 53 extends across each pair of LED arrays as shown in Figure 1. 4238966_1 (GHMatters) P91385.AU.1 10/04/13 -5 Optics The optics of the floodlight 10 are shown with particular reference to Figures 6 to 8. As mentioned 5 above each bank of LEDs comprises fourteen spaced LEDs in two spaced rows of seven. A lens assembly 60 is positioned over the LEDs and an outer lens 52 or 53 is positioned over the adjacent banks of LEDs to provide the closed off finish as shown in Figure 1. As shown in 10 Figures 6 and 7 the inner lens 60 is a total internal reflection lens (TIR). A rectangular moulded plastics tray 61 has two rows of seven lens 62 located in spaced parallel rows. The lens have a free-form formation with the larger end 64 at the top of lens 62 and the smaller 15 inner end 65 position above the LED 50. As shown in Figure 6 the light emanating from the LED 50 is reflected and refracted on free-form surfaces of the lens to exit as a substantially parallel series of beams. The outer lens 52, 53 is transparent plastic with a substantially planar 20 outer surface 54 and a formed undersurface 55. The formed undersurface 55 causes a refraction of the beams to assume the outward spread shown in Figure 6. The rectangular tray 61 that constitutes the TIR lens 60 has four legs 66 in opposed corners to facilitate attachment to the circuit 25 board supporting the LEDs 50. The outer lens 52, 53 is a single rectangular piece that covers 2 banks of LEDs with radiused edges 57 on the top, bottom and sides as shown in Figure 1. The mounting of the TIR lens 61 and LED circuit board to the housing 11 is as shown in Figure 9B. The 30 lens 61 is held to the circuit board 38 and housing 11 by screws 65 that extends into a recess 66 position directly over one of the cooling fins 16 to ensure that the screw and the associated componentry causes minimum airflow disturbance. 35 Airflow 4238966_1 (GHMatters) P91385.AU.1 10/04/13 - 6 As described above the rear of the housing 11 has a series of parallel fins 16 extending from the top to the bottom and across the longer sides of the housing. The enclosure has two parallel open spaces 40, 41 on the front 5 face between the banks 30-33 of LEDs 50 and drivers 34, 35. The fins 16 at the rear of the housing 11 extend across the base of these open spaces 40, 41 as shown in Figures 4 and 5. The heat generated by the LEDs 50 as well as the drivers 34, 35 causes air to be drawn into the 10 rear of the enclosure 12 past the fins 16 to escape in an upward direction as shown in Figure 4 through the open channels 40, 41 which act as air vents. The separation of the LEDs 50 from the heat generated from the drivers 34, 35 is critical to ensure satisfactory airflow as shown in 15 Figures 4, 11a and lb. The LEDs 50 and the circuit board 38 constitute a heat source region which is separated from the driver board 34, 35 region by the air vents 40, 41 with critical flow geometry. The air vents allow sufficient airflow over the cooling fins 16 on heat sink 20 in all orientations of the floodlight 10 from horizontal to 20' from vertical as shown in Figure 11a. This arrangement provides optimum cooling even in a still air environment with the heat of the LEDs 50 and circuit board 38 drawing air into the unit. A view of the airflow from 25 above can be seen in Figure lb with the air coming in from either side of the rear, flowing through the unit 10 past the air vents 40, 41 and taking heat away from the LEDs 50 and LED circuit boards assembly 38 as well as the printed circuit boards assembly 38 that constitute the 30 drivers 34, 35. The heat sink at the rear of the housing 11 has an important role to also draw heat off the LED boards 38 and printed circuit boards 34, 35 as shown in Figures 4 and 5. The fins 16 are positioned directly behind the LEDs 50 to provide the shortest and direct path 35 of conduction of heat away from the LEDs 50 as shown in Figures 9a and 9b. 4238966_1 (GHMatters) P91385.AU.1 10/04/13 -7 Structural features The floodlight 10 as described above is designed to be particularly robust so it can operate satisfactorily in 5 hot, dirty environments. The position of the screws 46 that hold the circuit boards 38 of each LED bank 30-33 are equally spaced to ensure an even force distribution. The join between the arms 22, 23 and the bracket 20, 21 at the rear of the housing is positioned as close to centre of 10 gravity as possible to reduce moments that would be caused by high shocks forces. The housing 11 inclination relative to the mast or post is adjustable by turning the brackets 20, 21 on the circular plate 24 and then locking the plate 24 is the desired position by the tightening up 15 a screw 29 that can be located in spaced slots 28 around the periphery of the plate 24, see Figure 3. The wiring 70 for the light extends through an aperture 71 in the centre of the rear of the housing 11 and the plug and socket arrangements that couple the printed circuit boards to the 20 LEDs 50 to the drivers 34, 35 and the associated wiring are designed to be robust and hard wearing. A further mounting feature is illustrated in Figure 13 whereby a stainless steel bolt 75 is fitted through the 25 front of the housing 11 into the base of the housing from the inside of the enclosure 12 to engage a nut 76 and washer 77 at opposite ends of each bracket 20, 21. A rubber dampening bush 78 is located under the head of each bolt 75 to dampen vibration and also acts as an insulator 30 against bi-metallic corrosion caused by the bracket 20 and the housing 11 being of dissimilar metals. In the claims which follow and in the preceding description of the invention, except where the context 35 requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, 4238966_1 (GHMatters) P91385.AU.1 10/04/13 - 8 i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention. 4238966_1 (GHMatters) P91385.AU.1 10/04/13
    权利要求:
    Claims (11)
    [1] 1. A floodlight comprising an enclosure adapted to contain a plurality of banks of LEDs, at least one 5 driver for the LEDs positioned remote from the LEDs, the enclosure including a heat sink and air vents positioned between the banks of LEDs and the driver wherein heat generated by the LEDs and driver draws air into the enclosure past the heat sink to exit 10 through the air vents to cool the floodlight.
    [2] 2. The floodlight according to claim 1 wherein each bank of LEDs is positioned beneath a total internal reflection (TIR) lens array and an outer lens covers 15 the TIR lens array.
    [3] 3. The floodlight according to either claim 1 or claim 2 wherein the heat sink comprises a series of spaced metallic fins on the rear of the enclosure. 20
    [4] 4. The floodlight according to any one of the preceding claims wherein the enclosure has brackets on either side pivotally secured to an arm structure adapted to be located on the end of a post or mast. 25
    [5] 5. The floodlight according to any one of the preceding claims wherein the banks of LEDs, air vents and driver are mounted in a single plane. 30
    [6] 6. The floodlight according to any one of the preceding claims wherein the banks of LEDs are positioned on either side of two drivers with air vents between the drivers and the LEDs. 35
    [7] 7. The floodlight according to any one of the preceding claims wherein each bank of LEDs comprises spaced LEDs on a circuit board.
    [8] 8. The floodlight according to any one of the preceding 4238966_1 (GHMatters) P91385.AU.1 10/04/13 - 10 claims wherein the light output is between 0.1 and 0.2 watts per lumen, preferably 0.14 watts per lumen or between 50 and 100 lumens per watt preferably 71.4 lumens per watt. 5
    [9] 9. The floodlight according to claim 8 wherein the floodlight has an operating life of greater than 50,000 hours and is designed to operate at temperatures ranging between -40'C to 70 0 C. 10
    [10] 10. The floodlight according to any one of the preceding claims wherein the driver comprises a printed circuit board supporting electrical componentry to step down and rectify the input power 15 to 24 volts DC.
    [11] 11. The floodlight substantially as herein described with reference to and as illustrated in the accompanying drawings. 20 4238966_1 (GHMatters) P91385.AU.1 10/04/13
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    同族专利:
    公开号 | 公开日
    AU2013203425B2|2014-12-04|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    US20030031028A1|2001-08-09|2003-02-13|Murray Timothy B.|Vehicle emergency warning light having TIR lens, LED light engine and heat sink|
    AU2008293539B2|2007-08-27|2014-06-26|Dialight Corporation|LED based hazardous location light with versatile mounting configurations|
    法律状态:
    2015-04-02| FGA| Letters patent sealed or granted (standard patent)|
    优先权:
    申请号 | 申请日 | 专利标题
    AU2012904317||2012-10-03||
    AU2012904317A|AU2012904317A0||2012-10-03|A Floodlight|
    AU2013203425A|AU2013203425B2|2012-10-03|2013-04-10|A Floodlight|AU2013203425A| AU2013203425B2|2012-10-03|2013-04-10|A Floodlight|
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