Mechanically sealed LED cavities for unmanned aerial vehicle (UAV) attachments

A method of providing improved ingress protection for a light emitting diode (LED) assembly in an unmanned aerial vehicle (UAV), the method comprising:

• providing an ingress protection stack to protect an LED assembly having multiple LEDs from an environmental ingress, the ingress protection stack including:
• an LED base layer,
• seal components,
• a baffle,
• a heatsink, and
• a cover glass;
• wherein providing the ingress protection stack includes mechanically securing the baffle through the LED base layer to the heatsink to establish a thermal contact between the LED base layer and the heatsink for thermal conduction;
• compressing the seal components against the LED base layer by the baffle to provide ingress protection;
• and
• enclosing the LED assembly within sealed LED cavities to prevent dust or water ingress, thereby forming dry zones around the LEDs and enabling flight in varied environmental conditions without risk of damage to the LEDs.

An unmanned aerial vehicle (UAV) including a night flight module arranged thereon, the night flight module comprising:

• a mechanically sealed light emitting diode (LED) assembly for improved ingress protection, the mechanically sealed LED assembly including an LED assembly comprising:
• multiple LEDs enclosed within sealed LED cavities configured to prevent dust or water ingress, thereby forming dry zones around the LEDs and enabling flight in varied environmental conditions;
• and
• an ingress protection stack comprising a plurality of parts configured to provide ingress protection to the LED assembly, the ingress protection stack including:
• an LED base layer,
• seal components,
• a baffle,
• a heat-dissipating component, and
• a cover glass,
• wherein the seal components are compressed against the LED base layer by the baffle to provide the ingress protection, and the baffle is mechanically secured through the LED base layer to establish thermal contact between the heat-dissipating component and the LED base layer for thermal conduction.

A mechanically sealed light emitting diode (LED) assembly with an improved ingress protection and for use in an unmanned aerial vehicle (UAV), the mechanically sealed LED comprising:

• an LED assembly including:
• multiple LEDs enclosed within sealed LED cavities configured to prevent dust or water ingress, thereby forming dry zones around the LEDs and enabling flight in varied environmental conditions without risk of damage to the LEDs;
• and
• an ingress protection stack configured to provide ingress protection to the LED assembly, the ingress protection stack including:
• an LED base layer,
• seal components,
• a baffle, and
• a cover glass,
• wherein the seal components are compressed against the LED base layer by the baffle to provide the ingress protection, and the cover glass is a clear optical glass with a black mask configured to enhance optical transmission from the LEDs while blocking peripheral light to reduce glare or reflections interfering with one or more cameras of the UAV.

A mechanically sealed light emitting diode (LED) assembly with an improved ingress protection and for use in an unmanned aerial vehicle (UAV), the mechanically sealed LED comprising:

• an LED assembly including:
• multiple LEDs enclosed within sealed LED cavities configured to prevent dust or water ingress, thereby forming dry zones around the LEDs and enabling flight in varied environmental conditions without risk of damage to the LEDs;
• and
• an ingress protection stack configured to provide ingress protection to the LED assembly, the ingress protection stack including:
• an LED base layer,
• seal components,
• a baffle, and
• a cover glass,
• wherein the seal components are compressed against the LED base layer by the baffle to provide the ingress protection, and the LED base layer is a base layer of the ingress protection stack and the cover glass is an exterior layer of the ingress protection stack.

A mechanically sealed light emitting diode (LED) assembly with an improved ingress protection and for use in an unmanned aerial vehicle (UAV), the mechanically sealed LED comprising:

• an LED assembly including:
• multiple LEDs enclosed within sealed LED cavities configured to prevent dust or water ingress, thereby forming dry zones around the LEDs and enabling flight in varied environmental conditions without risk of damage to the LEDs;
• and
• an ingress protection stack configured to provide ingress protection to the LED assembly, the ingress protection stack including:
• an LED base layer,
• seal components,
• a baffle, and
• a cover glass,
• wherein the seal components are compressed against the LED base layer by the baffle to provide the ingress protection, and the seal components comprise a silicone rubber compressible seal, a stainless steel stiffener, and an adhesive layer.

A method of providing improved ingress protection for a light emitting diode (LED) assembly in an unmanned aerial vehicle (UAV), the method comprising:

• providing an ingress protection stack to protect an LED assembly having multiple LEDs from an environmental ingress, the ingress protection stack including:
• an LED base layer,
• seal components,
• a baffle, and
• a cover glass;
• compressing the seal components against the LED base layer by the baffle to provide ingress protection;
• and
• enclosing the LED assembly within sealed LED cavities to prevent dust or water ingress, thereby forming dry zones around the LEDs and enabling flight in varied environmental conditions without risk of damage to the LEDs, wherein enclosing the LEDs within the sealed LED cavities includes positioning the cover glass formed of a clear optical glass with a black mask, the cover glass being configured to (a) enhance optical output from the LEDs, and (b) block peripheral light to reduce glare or reflections that could interfere with one or more cameras of the UAV.

A method of providing improved ingress protection for a light emitting diode (LED) assembly in an unmanned aerial vehicle (UAV), the method comprising:

• providing an ingress protection stack to protect an LED assembly having multiple LEDs from an environmental ingress, the ingress protection stack including:
• an LED base layer,
• seal components,
• a baffle, and
• a cover glass,
• wherein providing the ingress protection stack includes providing the LED base layer as a base layer of the ingress protection stack and the cover glass as an exterior layer of the ingress protection stack;
• compressing the seal components against the LED base layer by the baffle to provide ingress protection;
• and
• enclosing the LED assembly within sealed LED cavities to prevent dust or water ingress, thereby forming dry zones around the LEDs and enabling flight in varied environmental conditions without risk of damage to the LEDs.

A method of providing improved ingress protection for a light emitting diode (LED) assembly in an unmanned aerial vehicle (UAV), the method comprising:

• providing an ingress protection stack to protect an LED assembly having multiple LEDs from an environmental ingress, the ingress protection stack including:
• an LED base layer,
• seal components,
• a baffle, and
• a cover glass,
• wherein providing the ingress protection stack includes providing the seal components including a silicone rubber compressible element, a stainless steel stiffener, and an adhesive layer;
• compressing the seal components against the LED base layer by the baffle to provide ingress protection;
• and
• enclosing the LED assembly within sealed LED cavities to prevent dust or water ingress, thereby forming dry zones around the LEDs and enabling flight in varied environmental conditions without risk of damage to the LEDs.