Aircraft position light assembly

Many large, commercial aircraft navigation lights use incandescent or halogen light modules. These light modules are unpredictable when they fail. Thus, it can be expensive to have to replace these light modules at the time of failure, instead of at a preknown time for scheduling of such maintenance. Light-emitting-diodes (LEDs) are slowly replacing navigation and position lights on commercial aircraft. Some of the benefits include longer life, lower power, lighter module packages, etc. However, many of the existing LED systems are not designed to fit into existing light module housings, thereby making replacement of incandescent or halogen lamps with LEDs an expensive and time-consuming process.

Miniaturized forward position light universal module—LED—Meet FAA photometric requirements of aircraft forward position light using a universal, compact, LED module that can be installed in a variety of aircraft wing-tip cavities. Utilize a “blade” form factor to optimize space usage while maximizing photometric performance at historically weak areas of the FAA required angular intensity pattern.

The arrangement of the LEDs, reflectors, and light baffling surfaces allow for the smallest possible physical footprint and best possible performance at 90-degree vertical angular intensity points from an LED light module. Indirect-view reflector orientations maximize reflector light collection and redirection into critical portions of the angular intensity pattern while allowing direct-LED view to the wide-angle intensity zones (110-degrees horizontal and 90-degrees vertical).

Preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings:

FIG. 1 illustrates a partial perspective view of a wingtip assembly that includes twp light-emitting diode (LED) module formed in accordance with the present invention;

FIG. 2 illustrates a side view of the wingtip assembly of FIG. 1 ;

FIG. 3 illustrates a side view of an LED wingtip assembly used in FIGS. 1 and 2 ;

FIG. 4-1 illustrates a perspective view of an LED module;

FIG. 4-2 illustrates a top view of the LED module of FIG. 4-1 ;

FIG. 4-3 illustrates an exploded view of the LED module of FIG. 4-1 ;

FIG. 5 illustrates a side view of a frame with the support bracket of FIG. 3 in an open and closed position;

FIG. 6 illustrates a perspective rear view of the frame and the support bracket of FIG. 5 in an open position;

FIG. 7 illustrates a view of the support bracket separated from the frame;

FIG. 8-1 illustrates a perspective view of an LED module formed in accordance with an alternate embodiment of the present invention;

FIG. 8-2 illustrates a bottom view of the LED module shown in FIG. 8-1 ; and

FIG. 8-3 illustrates an exploded view of the LED module shown in FIG. 8-1 .

As shown in FIGS. 1-3 , a wingtip assembly 40 includes a wing surface 42 with a cavity for housing position lights 50 . The wingtip assembly 40 also includes an access panel 60 . The position lights 50 are covered by a lens 52 . The position lights 50 include two light-emitting diode (LED) modules 54 . The LED modules 54 are mounted on a support base 70 that is rotatably attached to a support bracket 64 (see FIGS. 5-7 ).

FIGS. 4-1 , 4 - 2 , 4 - 3 illustrate an exemplary LED module 54 . The LED module 54 includes a circuit board 56 that includes two major surfaces. Each of the major surfaces includes metallic traces (not shown). Two or more metallic traces (not shown) are embedded within the circuit board 56 . A single circuit board design may also be used.

A first reflector unit (forward 58 - 1 and aft 58 - 2 ) is mounted on the circuit board 56 at a first end. A second reflector unit is mounted on the circuit board 56 on the side of the circuit board 56 opposite the first reflector unit. In one embodiment, the reflector units are a molded plastic structures that include a metalized (or other reflective) interior for allowing reflection of light produced by LEDs 57 - 1 , 57 - 2 . The LEDs 57 - 1 , 57 - 2 (on both sides of the circuit board 56 ) mount to the circuit board 56 through the respective reflector unit. In one embodiment, the forward and aft reflectors 58 - 1 and 58 - 2 are formed as a single piece and may be mounted to the circuit board 56 by any of a number of methods, such as rivets, screws, epoxy, etc. The reflectors 58 - 1 , 58 - 2 are shaped and positioned on the circuit board 56 in order to provide a desired deflection pattern of the light produced by the LEDs 57 - 1 , 57 - 2 .

In one embodiment, the metalized surface on the reflector units is applied using a vacuum metallization process. A clear topcoat is applied for protecting the metalized surface.

In one embodiment, the LEDs 57 - 1 , 57 - 2 include three metallic pads. One of the pads is a heat sink pad and the other two electrically connect the LED to a remote power source. Example manufacturers of the LEDs 57 - 1 and 57 - 2 include, but are not limited to, Cree, Philips, Osram, Nichia and Sharp. The LEDs 57 - 1 and 57 - 2 are surface mounted to the circuit board 56 such that the heat sink pads of the LEDs 57 - 1 and 57 - 2 attach to respective surface-mounted electrical metallic traces. The other two pads of the LEDs 57 - 1 and 57 - 2 connect to metallic vias that pass through the circuit board 56 to connect to the internally embedded electrically isolated metallic traces.

The LED module 54 also includes two L-shaped brackets 62 that attach at approximately a center position of the circuit board 56 along a longitudinal axis. In one embodiment, screws are used to attach the L-shaped bracket 62 to the circuit board 56 . Other fastening means may be used. The L-shaped brackets 62 are preferably a metal material, such as aluminum, and are positioned so that they come in contact with the heat sink surface traces on the surface of the circuit board 56 . Flanges (bottom of the L) perpendicular to the portion of the L-shaped brackets 62 attached to the circuit board 56 include holes that allow the L-shaped brackets 62 to be attached to the support base 70 using fastening devices. The L-shaped brackets 62 may be a single piece with a slot for receiving the circuit board 56 .

The LED circuit board 56 includes a second end that extends below the L-shaped brackets 62 opposite where the LEDs are mounted. The second end of the circuit board 56 , in one embodiment, includes attachment devices for allowing connection to wires that are coupled to a power source (not shown). Also, in one embodiment, the second end of the circuit board 56 includes circuit components (not shown) for performing various operations relative to the LEDs 57 - 1 and 57 - 2 . For example, the electronic components may include a timer(s), a temperature sensor, a near-end-of-life indicator LED, power control circuitry, LED bypass device(s) (e.g., SCR, diodes) and/or other circuit components.

FIGS. 5-7 illustrate functionally operational positions for the components of the position lights 50 in accordance with one embodiment. The support base 70 is rotatably mounted to the support bracket 64 at support hooks 92 via a rod 90 that is connected to arms 88 that extend from a forward end of the support base 70 . In order to perform maintenance of the position lights 50 , one accesses the access panel 60 and releases a securing bolt that connects the support base 70 to the support bracket 64 then rotates the support base 70 away from the support bracket 64 . Then the support base 70 can be easily disconnected from the support bracket 64 for repair or replacement, see FIG. 7 . Other manufacturers require that the bulbs be accessible and replaceable by removing the outer lens and outer lens retainer.

FIGS. 8-1 , 8 - 2 , 8 - 3 illustrate a light module 120 that includes a circuit board 126 having LEDs and reflectors 130 attached at a first end similar to the LED modules 54 described above. Various electronic components and/or electrical connector 140 are mounted at an end of the circuit board 126 opposite where the LEDs and reflectors 130 are mounted. One or more bracket devices 144 attach to the circuit board 126 between the LEDs/reflectors 130 and the electronic components and/or the electrical connector 140 . The one or more bracket devices 144 connect the circuit board 126 to the support base 70 and provide a heat sink for surface mounted heat sink traces. The wire port 140 includes a plug for receiving power and outputting signals produced by the electronic components. The electronic components may include a timer, a temperature sensor, power control circuitry, and/or other devices.

While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.