The client is a UK based manufacturer of low voltage lighting with a comprehensive range of lights for reading, machinery and inspection. The design brief was to design an Industrial Sewing Machine Light Head that would be cool to the touch and had an easy, no tool access for replacement of the light source.
The client uses 12V Dichroic and Capsule Bulbs for different applications and although they mount into the same holder they have different heat and light characteristics. In general dichroics radiate heat backwards and capsule bulbs radiate heat forwards.
The first task was to determine the heat characteristics of each light source and several combinations of reflector type and front glass to determine how much heat had to be dissipated. The problem of heat was solved by designing the head with a double skin which insulated the hot exhaust air from the outer body with another layer of air.
The product consisted of the Head and Body injection moulded parts which were attached to each other by a quarter turn bayonet. The design was developed on CAD and refined though fully working prototypes before signing off the designs for manufacture.