11th Oct 2021
Lighting the Way for a Leading Commercial Retailer
Customer Overview
Our customer is a top-tier retailer in the commercial high bay lighting sector. They came to us with an exciting vision: to create a compact, ultra-bright LED light that was flicker-free, emitted minimal EMC noise, and could be linked together to form powerful floodlights—ideal for stadiums, training grounds, and other large open spaces.
Product Brief
The goal was clear but ambitious. They needed help developing an LED light that delivered:
- 7000 lumens on a compact 140mm x 140mm board
- Low wattage operation
- Compatibility with both 240V and 110V
- Minimal EMC interference to avoid disrupting nearby electronics
- A small form factor that could be connected in arrays
- A robust IP66 rating or better for outdoor use
Challenges & Solutions
This project came with its fair share of technical hurdles. Here’s how we tackled them:
1. Managing Heat Dissipation
Driving LED chips to such high brightness generates significant heat. Using Design for Manufacturing principles, we started with the customer’s circuit board and focused on thermal management. Our design team created a compact yet strong casting (housing) and paired it with an extruded aluminium heatsink. This combination maximized surface area for heat dissipation—crucial for maintaining performance at full brightness.
We also had to address heat transfer between two separate body components. After testing various thermal interface materials, we found that a graphite thermal sheet offered the best balance of performance and cost.
2. Achieving IP66 Rating
To meet the IP66 requirement, we needed a reliable seal between the lens bezel and the main housing. We explored a range of materials, evaluating them for UV resistance, rigidity, longevity, colour stability, and cost. The final choice was guided by our clamping strategy, which determined how much force the seal material would need to withstand.
3. Reducing EMC Noise
While linear drivers helped reduce electromagnetic interference, they didn’t go far enough. Our team innovated further by mounting the drivers in sealed aluminium housings, which effectively absorbed unwanted signals and brought EMC noise down to a superior level.
Conclusion
The final product exceeded expectations. It ran at optimal temperatures to minimize lumen depreciation, achieving outstanding results in heat dissipation, EMC noise reduction, and IP rating, and earned CE, UL, and ATEX certifications—all without compromising on cost or the original product vision.