Conical Finned LED Heat Sink with Radial Air Channels
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Solution Overview
Problem
Existing power LED lighting systems face challenges in efficiently dissipating heat without the use of fans, which leads to reduced efficiency, increased energy consumption, and design limitations, especially when multiple LED chips are used, as they require large finned surfaces for natural heat dissipation, compromising aesthetics and performance.
Innovation Solution
A finned support body made of heat-conductive material with a conical shape and variable fin diameters is designed to enhance heat dissipation, featuring a front seat for the power LED chip and a rear finned portion with strategically placed slits and holes for improved air circulation and heat exchange, allowing for efficient cooling without fans.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If finned radiator elements are used for heat dissipation without fan, then energy consumption is reduced and reliability is improved, but the required finned surface area becomes very large compromising aesthetics and increasing device size
Solution Approach 1:
The patent applies local quality by creating variable fin geometries with different heights, thicknesses, and spacing in different radial zones. The fin height increases from inner to outer zones, and the spacing between fins varies to optimize heat transfer in each region, allowing efficient heat dissipation in a compact overall structure.
Solution Approach 2:
The patent transitions from conventional planar fin arrangements to a three-dimensional radial fin structure extending outward from the central mounting area. This dimensional change allows the heat dissipation surface to utilize the radial space efficiently, increasing the effective heat exchange area without proportionally increasing the device footprint.
2Temperature
If forced air circulation with fan is used, then heat dissipation efficiency is improved, but energy consumption increases and mechanical reliability decreases
Solution Approach 1:
The patent extracts the fan component from the cooling system entirely, replacing active forced convection with passive natural convection. The redesigned fin structure compensates for the removed fan by providing optimized geometry that enhances natural heat transfer from the LED mounting area outward to the ambient environment.
Solution Approach 2:
The cooling system becomes self-service through natural convection, where the temperature difference between the hot fin bases and cooler ambient air automatically drives air flow through the fin structure. The fin geometry is designed to maximize this natural convection effect without requiring external mechanical assistance.
3Temperature
If large finned surfaces are used for natural cooling, then heat dissipation is improved, but the device size and aesthetic appearance are compromised
Solution Approach 1:
The finned structure is segmented into multiple radial zones with distinct fin characteristics. Each zone is optimized for its specific thermal and aerodynamic conditions, allowing the overall structure to achieve high heat dissipation efficiency in a compact form factor rather than requiring a single large uniform fin surface.
Solution Approach 2:
The patent employs asymmetric fin geometry where fin height, thickness, and spacing vary deliberately across different radial positions. This asymmetry is optimized to match the heat generation distribution and convection patterns, achieving superior heat dissipation in a space-efficient design compared to symmetric conventional fins.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a high heat dissipation efficiency with reduced size, improved heat exchange, and cost-effective manufacturing, enabling the use of high-power LED chips in a compact and aesthetically pleasing design while minimizing energy consumption and mechanical wear.
Implementation Method 1
an conductive element made of a heat-conductive material, said conductive element having a front portion with a front seat for a power LED chip and a rear finned portion
Implementation Method 2
when exposed to outside air, allow a suitable dispersion of the heat generated by a power LED chip
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A finned body (100) comprises a plurality of fins (Ai) at a distance (d,) from one another, and each fin Ai extends from a root of material (3) that has a circular cross section of diameter (F?). The root (3) extends from a support base (1) with a housing support (2) for a power LED chip (20). The method for making the finned body (100) comprises the steps of prearranging a raw block (10) on the front face of which (1a) is formed the housing support (2) for a power LED chip (20), then on the element (10) fins (A1), (A2), (A3),... (An), (Ai), are made starting at a measured distance (D) from the front seat (2), in order to form the support base (1) of thickness (D). The first plane slit (F1) and the subsequent slits are made by progressively moving the cutting tool (42) until the finned body (100) is obtained. The root (3) of the fins (Ai) may have a decreasing conical shape in order to optimize the cooling step. A power LED chip (20) and a reflector body (110) may be mounted on the finned body (100), at the front seat (2). Through holes (8a or 8b) may be made on the front seat (2), such holes crossing the finned body (100) starting from the front seat (2) towards last fin An, which is arranged to receive electrical supply wires of the power LED chip (20) and/or to allow an axial air circulation and to assist heat exchange.