Exterior Aircraft Light And Aircraft Comprising The Same

Abstract

An exterior aircraft light includes a mounting board, having an upper side, a lower side and a plurality of side faces; at least one LED, arranged on the upper side of the mounting board; and a mounting board enclosure and lens structure, wherein the mounting board enclosure and lens structure comprises a lens arranged over the at least one LED for shaping an output light intensity distribution of the exterior aircraft light and a covering layer arranged on the upper side, the lower side and the plurality of side faces of the mounting board, wherein the mounting board enclosure and lens structure is an integral silicone structure.

Claims

1. An exterior aircraft light, comprising: a mounting board, having an upper side, a lower side and a plurality of side faces, at least one LED, arranged on the upper side of the mounting board, and a mounting board enclosure and lens structure, wherein the mounting board enclosure and lens structure comprises a lens arranged over the at least one LED for shaping an output light intensity distribution of the exterior aircraft light and a covering layer arranged on the upper side, the lower side and the plurality of side faces of the mounting board, wherein the mounting board enclosure and lens structure is an integral silicone structure.

2. The exterior aircraft light according to claim 1, wherein the mounting board enclosure and lens structure fully encloses the mounting board and the at least one LED.

3. The exterior aircraft light according to claim 1, wherein the mounting board enclosure and lens structure is overmolded over the mounting board and the at least one LED.

4. The exterior aircraft light according to claim 1, wherein the mounting board enclosure and lens structure is from a soft silicone.

5. The exterior aircraft light according to claim 1, further comprising a gas impermeable coating, coated over the mounting board enclosure and lens structure.

6. The exterior aircraft light according to claim 5, wherein the gas impermeable coating is a parylene coating.

7. The exterior aircraft light according to claim 1, wherein the covering layer has a top portion, arranged on the upper side of the mounting board, wherein the top portion has a thickness of between 0.25 mm and 2.5 mm, in particular between 1 mm and 2 mm.

8. The exterior aircraft light according to claim 1, wherein the covering layer has a bottom portion, arranged on the lower side of the mounting board, wherein the bottom portion has a thickness of between 0.5 mm and 4 mm, in particular of between 1 mm and 3 mm.

9. An exterior aircraft light, comprising: a mounting board, having an upper side, a lower side and a plurality of side faces, at least one LED, arranged on the upper side of the mounting board, and a mounting board enclosure and lens structure, wherein the mounting board enclosure and lens structure comprises a lens arranged over the at least one LED for shaping an output light intensity distribution of the exterior aircraft light and a covering layer, arranged on the upper side, the lower side and the plurality of side faces of the mounting board, wherein the lens and a first portion of the covering layer are from silicone and wherein a second portion of the covering layer is from a filler material.

10. The exterior aircraft light according to claim 9, wherein the first portion of the covering layer is arranged on the upper side, the plurality of side faces, and part of the lower side of the mounting board.

11. The exterior aircraft light according to claim 9, wherein the mounting board enclosure and lens structure fully encloses the mounting board and the at least one LED.

12. The exterior aircraft light according to claim 9, wherein the filler material is parylene.

13. The exterior aircraft light according to claim 9, further comprising a gas impermeable coating, coated over the lens and the first portion of the covering layer, with the gas impermeable coating being in particular a parylene coating.

14. The exterior aircraft light according to claim 9, wherein the exterior aircraft light is one of a navigation light, an anti-collision light, a landing light, a runway turnoff light, a taxi light, and a logo light.

15. An aircraft, comprising at least one exterior aircraft light according to claim 1, arranged on an outside of the aircraft.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Further exemplary embodiments of the invention are described in detail below with respect to the accompanying drawings, wherein:

[0033] FIG. 1 shows an aircraft in accordance with an exemplary embodiment of the invention, having a forward navigation light in accordance with an exemplary embodiment of the invention installed thereon;

[0034] FIG. 2 shows a perspective view of an exterior aircraft light in accordance with an exemplary embodiment of the invention;

[0035] FIG. 3a-3b shows cross-sectional views through the exterior aircraft light of FIG. 2;

[0036] FIG. 4 shows a cross-sectional view through an exterior aircraft light in accordance with another exemplary embodiment of the invention;

[0037] FIG. 5 shows a cross-sectional view through an exterior aircraft light in accordance with yet another exemplary embodiment of the invention.

DETAILED DESCRIPTION

[0038] FIG. 1 shows an aircraft 100 in accordance with an exemplary embodiment of the invention. The aircraft 100 is equipped with a forward navigation light 2, positioned in a left wing tip of the aircraft 100. The forward navigation light 2 is an exterior aircraft light in accordance with an exemplary embodiment of the invention. Only half of the aircraft 100 is depicted in FIG. 1. It is understood that the aircraft 100 is substantially symmetric with respect to its axis of longitudinal extension 102. Hence, a symmetric forward navigation light in accordance with an exemplary embodiment of the invention is provided in the right wing tip as well. The axis of longitudinal extension 102 is also the forward flight direction of the aircraft 100, when air borne.

[0039] The forward navigation light 2 has an output light emission distribution 104 over an angular region of 110° in a horizontal cross-sectional plane through the forward navigation light 2. The output light emission distribution 104 extends over an angular region from straight ahead, i.e. from the forward flight direction, to an angle of 110° counterclockwise. In the left portion of FIG. 1, it is illustrated that the output light emission distribution has three distinct output regions, namely a peak light intensity region between the forward flight direction of the aircraft and an angle of 10° therewith, a medium light intensity region between 10° and 20°, and a low light intensity region between 20° and 110°. The output light intensity is 40 cd in the peak light intensity region, 30 cd in the medium light intensity region, and 5 cd in the low light intensity region. In this way, the forward navigation light 2 is in compliance with Federal Aviation Regulation (FAR) requirements for forward navigation lights.

[0040] FIG. 2 shows an exterior aircraft light 2 in accordance with an exemplary embodiment of the invention in a perspective view. The exterior aircraft light 2 may be used as the forward navigation light 2 of the aircraft 100, depicted in FIG. 1.

[0041] The exterior aircraft light 2 comprises a mounting board 4 and an LED 6. The LED 6 is arranged substantially at the center of the mounting board 4. The mounting board 4 is a printed circuit board (PCB). The exterior aircraft light 2 further comprises four additional circuit components 10. In the exemplary embodiment of FIG. 4, the four additional circuit components 10 are a power supply circuit for controlling the drive current to the LED 6, a sensor for measuring relative luminous flux, and two indicator LEDs for indicating near end of life to service personnel. It is also possible that other circuit components, such as a control circuit and power storage circuits, for example capacitor circuits, are present. These additional circuit components 10 are provided for receiving power from a power supply, temporarily storing power and for supplying power to the LED 6 and for controlling the LED 6. Electric connectors are provided on the mounting board 4 that interconnect the LED 6 and the additional circuit components 10. When used as the forward navigation light 2 of the aircraft 100 of FIG. 1, the mounting board 4 my be arranged vertically, with the main light emission direction of the LED 6, i.e. the direction perpendicular to the mounting board 4 through the LED 6, being angled with respect to the forward flight direction of the aircraft 100.

[0042] The exterior aircraft light 2 further comprises a mounting board enclosure and lens structure 8. The mounting board enclosure and lens structure 8 is a one-piece silicone structure, also referred to as an integral silicone structure. The mounting board enclosure and lens structure 8 both encloses the mounting board with a silicone layer and forms a lens out of silicone arranged over the LED 6. In particular, the mounting board enclosure and lens structure 8 is comprised of a lens 82, arranged over the LED 6, and a covering layer, which in turn is comprised of a top portion 84, a bottom portion 86, and side portions 88. The top portion 84 of the covering layer is arranged on the upper side of the mounting board 4, i.e. on the side of the mounting board 4 that supports the LED 6. The bottom portion 86 of the covering layer is arranged on the lower side of the mounting board 4, i.e. on the side of the mounting board 4 that is opposite the LED 6. The side portions 88 of the covering layer are arranged on the side faces of the mounting board 4. As the mounting board 4 is a plate-like, generally quadratic structure, the side faces are much smaller in extension than the upper and lower sides of the mounting board 4.

[0043] In the exemplary embodiment of FIG. 2, the mounting board enclosure and lens structure 8 fully encloses the mounting board 4 and the LED 6. In other words, the mounting board enclosure and lens structure 8 fully surrounds the mounting board 4 and the LED 6, i.e. it covers the entire upper and lower sides as well as the side faces of the mounting board 4. The mounting board enclosure and lens structure 8 also encloses the four additional circuit components 10. The mounting board 4 and the LED 6 are completely encased by the mounting board enclosure and lens structure 8.

[0044] It is pointed out that a plurality of LEDs may be provided instead of the single LED 6 of the exemplary embodiment. For example, a one-dimensional or two-dimensional array of LEDs may be provided. The number and arrangement of LEDs may depend on the light intensity requirements of the particular application.

[0045] The mounting board 4 further comprises four through holes 12. In the production state depicted in FIG. 2, the four through holes 12 are also covered by the mounting board enclosure and lens structure 8. However, during assembly of the mounting board 4 to a housing of the exterior aircraft light or to the aircraft body, screws or bolts may be introduced through the through holes 12 for fastening the mounting plate 4. It is also possible that the through holes 12 are left free of silicone from the mounting board enclosure and lens structure 8. In such a case, the mounting board 4 and the LED 6 would still be considered fully enclosed, because the through holes would be filled with the screws during assembly of the exterior aircraft light. Still, no portion of the mounting board 4 or the LED 6 would be non-covered in the assembled state.

[0046] The mounting board 4 also comprises a slit 14, reaching through the mounting board 4 on one side of the LED 6. This slit 14 is configured to receive a near end of life detector. This near end of life detector may also be coupled to the control unit described above. The near end of life detector may capture some of the light emitted by the LED 6 and may deduce a state of degradation of the LED 6. It is therefore able to detect and indicate a near end of life condition. It is also possible that the near end of life detector is also arranged on the mounting board 4 and also enclosed by the mounting board enclosure and lens structure 8.

[0047] The mounting board enclosure and lens structure 8 of the exemplary embodiment of FIG. 2 is from a soft silicone material. The soft silicone material is overmolded over the mounting board 4, the LED 6, and the additional circuit components 10. In other words, the mounting board enclosure and lens structure 8 is produced via a molding operation onto the mounting board 4, the LED 6, and the additional circuit components 10.

[0048] FIG. 3 shows a cross-sectional view through the exterior aircraft light 2 of FIG. 2. The cross-sectional plane of FIG. 3 is a plane perpendicular to the plane of extension of the plate-like mounting board 4. In particular, the viewing direction of FIG. 3 is indicated by arrows A-A in FIG. 2. FIGS. 3a and 3b both show the same exterior aircraft light 2. For a clearer illustration of the components, FIG. 3a shows the exterior aircraft light 2 without any light rays. For a better illustration of the resulting output light intensity distribution, FIG. 3b shows the exterior aircraft light 2 with some exemplary light rays. For ease of illustration, the through holes 12 and the slit 14 are not shown in FIG. 3.

[0049] As already described above with respect to FIG. 2, the mounting board enclosure and lens structure 8 fully encloses the mounting board 4, the LED 6, and the additional circuit components 10, two of which are shown in FIG. 3, one in the cross-sectional plane of FIG. 3 and one behind the cross-sectional plane of FIG. 3. In addition to covering the upper side, the lower side and the side faces of the mounting board 4 as well as the LED 6 and the additional circuit components 10, the mounting board enclosure and lens structure 8 forms a lens 82 that has a substantial height above the mounting board 4. Its extension in the direction perpendicular to the mounting board 4 is about half of the extension of the mounting board 4 in its plane of extension in the cross-sectional view of FIG. 3.

[0050] The top portion 84 of the covering layer of the mounting board enclosure and lens structure 8 covers the upper side of the mounting board 4. With the mounting board 4 being a printed circuit board, having electrical connectors arranged thereon, the top portion 84 insulates these electrical connectors as well as the LED and the additional circuit components 10. In this way, the top portion 84 provides for an effective protection of electrostatic discharge. The top portion may have a height of about 1.5 mm, thus providing effective electrostatic discharge protection up to high voltages.

[0051] The bottom portion 86 of the covering layer of the mounting board enclosure and lens structure 8 covers the lower side of the mounting board 4. It provides a structure of effective heat transport away from the mounting board 4. In particular, it provides a heat bridge between the mounting board 4 and a support structure, such as a housing, to which the mounting board is fastened. In this way, the heat generated during operation of the exterior aircraft light can be effectively transported from the mounting board 4 to the housing, which acts as a heat sink.

[0052] The side portions 88 of the covering layer of the mounting board enclosure and lens structure 8 connect the top portion 84 to the bottom portion 86. In this way, a full enclosure of the mounting board 4 and the LED 6 is achieved. The mounting board enclosure and lens structure 8 does not have any free edge. Hence, no point of the mounting board enclosure and lens structure 8 poses a great danger of starting to peel off of the mounting board 4 inadvertently.

[0053] In FIG. 3b, the conditioning of the output light intensity distribution by the lens 82 is illustrated via exemplary light rays 60. The exemplary light rays 60 are light rays, as emitted by the LED 6 during operation of the exterior aircraft light 2. The lens 82 has a first surface 82a, which is a surface of total internal reflection. Further, the lens 82 has a second surface 82b, which is a surface of refraction. All light from the LED 6 leaves the lens 82 via the second surface 82b, i.e. via a refractive process. Some of the light from the LED 6 is internally reflected within the lens 82 at the first surface 82a, before leaving the lens 82 via the second surface 82b. In this way, a strong collimation of light in the angular range of between 100° and 110°, as measured with respect to the upper side of the mounting board 4, is achieved. The output light intensity becomes smaller with smaller angles with respect to the upper side of the mounting board 4. In this way, an exterior aircraft light having the output light intensity distribution of FIG. 1 may be provided. When assembled at a suitable angle in the wing tip of the aircraft, a suitable forward navigation output light intensity distribution is achieved. It is pointed out that there are other ways of reaching a suitable output light intensity distribution via other geometries of the lens 82. Also, other kinds of exterior aircraft lights may have other kinds of lens geometries for being suitable for the application in question.

[0054] FIG. 4 shows a cross-sectional view through an exterior aircraft light 2 in accordance with another exemplary embodiment of the invention. The exterior aircraft light 2 of FIG. 4 is similar to the exterior aircraft light 2 of FIG. 3, and the viewing direction and cross-sectional plane of FIG. 4 are identical to FIG. 3. Like elements are referred to with like reference numerals, and a description thereof is omitted for brevity.

[0055] In particular, the exterior aircraft light 2 of FIG. 4 is identical to the exterior aircraft light 2 of FIG. 3, with the exception that a parylene coating 20 is provided. The parylene coating is coated onto the entire mounting board enclosure and lens structure 8, i.e. it covers the entire outer surface of the mounting board enclosure and lens structure 8. The parylene coating 20 serves two purposes. First, the parylene coating is gas impermeable and protects the mounting board enclosure and lens structure 8 in the highly adverse operating conditions of exterior aircraft lights, in particular from corrosive gases. In particular, when an exterior aircraft light is placed close to a turbine exhaust, the parylene coating is an effective means of blocking the aggressive exhaust gases from the mounting board enclosure and lens structure 8. Second, after deposition, the parylene coating 20 forms a fairly rigid structure, thus forming a corset or case around the mounting board enclosure and lens structure 8. In particular, the mounting board 4 and the parylene coating 20 jointly provide enhanced stability to the mounting board enclosure and lens structure 8.

[0056] FIG. 5 shows a cross-sectional view through an exterior aircraft light 2 in accordance with yet another exemplary embodiment of the invention. The exterior aircraft light 2 of FIG. 5 is similar to the exterior aircraft light 2 of FIG. 3, and the viewing direction and cross-sectional plane of FIG. 5 are identical to FIG. 3. Like elements are referred to with like reference numerals, and a description thereof is omitted for brevity.

[0057] In particular, the exterior aircraft light 2 of FIG. 5 is identical to the exterior aircraft light 2 of FIG. 3, with the exception that the mounting board enclosure and lens structure 8 is a composite structure of two materials that jointly enclose the mounting board 4 and the LED 6. In particular, the mounting board enclosure and lens structure 8 of FIG. 5 has two different materials that jointly cover the lower side of the mounting board 4. The lens 82, the top portion 84 of the covering layer, the side portions 88 of the covering layer, and an outer portion 86′ of the bottom portion 86 of the covering layer are made from a one-piece soft silicone structure, as described above. An inner portion 90 of the bottom portion 86 of the covering layer is made from a filler material. The filler material 90 fills the silicone gap in the mounting board enclosure and lens structure 8, such that the mounting board enclosure and lens structure 8 as a whole fully encloses the mounting board 4, the LED 6 and the additional circuit components 10. A part of the silicone structure and the filler material 90 jointly form the bottom portion 86 of the covering layer of the mounting board enclosure and lens structure 8. In this way, there is also no edge of the silicone structure, such that the risk of the silicone structure peeling off inadvertently is kept low.

[0058] The filler material 90 is parylene in the exemplary embodiment of FIG. 5. The thickness of the filler material 90 is less than the thickness of the outer portion 86′ of the silicone structure arranged on the lower side of the mounting board 4. However, it is also possible that the thicknesses are substantially the same, such that the mounting board 4 can be placed onto a housing of the exterior aircraft light 2 or the like with an even surface.

[0059] It is also possible that the embodiments of FIGS. 4 and 5 are combined, i.e. that the silicone structure has the shape shown in FIG. 5 and that a parylene coating fully encloses the silicone structure and the mounting board 4, thus filling the gap in the silicone structure at the lower side of the mounting board 4 and coating the entire silicone structure.

[0060] It is further pointed out that the partitioning of the covering layer between the silicone structure and the filler material, i.e. the splitting up of mounting board area between the silicone structure and the filler material, may be different. It is for example possible that only the portion of the mounting board enclosure and lens structure 8 on top of the upper side of the mounting board 4 is from silicone. The filler material then has an adapted extension that still ensures a full enclosure of the mounting board 4 by the combination of the silicone structure and the filler material.

[0061] While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.