Foamed Metal Heat Sink for Drone LED Weight Reduction
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Solution Overview
Problem
Existing drone lighting systems are limited by low power LEDs and heavy conventional heat sinks, which restrict the ability to dissipate heat without increasing weight or size, thereby limiting the power and efficiency of drone lighting.
Innovation Solution
A lightweight and compact heat sink design using a foamed metal matrix thermally bonded to a copper or aluminum puck, combined with a single circuit board co-locating LEDs and driver electronics, to create a more efficient and powerful LED light fixture for drones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heat sinks with metal fins or pins are used, then heat dissipation capability is improved, but weight increases significantly
Solution Approach 1:
The patent applies porous metal foam material to create a heat sink that provides large surface area for heat dissipation while maintaining low weight. The porous structure allows efficient thermal conduction and convection without requiring heavy solid metal fins, directly resolving the contradiction between heat dissipation capability and weight.
Solution Approach 2:
The patent uses composite construction combining metal foam with copper or aluminum plates, creating a hybrid material system that optimizes both thermal conductivity and weight characteristics. This composite approach enables effective heat dissipation while keeping the overall heat sink weight low for drone applications.
2Illumination intensity
If LED power is increased to provide general illumination, then light output is improved, but heat generation increases requiring heavier cooling
Solution Approach 1:
The porous metal foam heat sink enables the LED to operate at higher power levels by efficiently dissipating the increased heat generation. The large surface area-to-weight ratio of the foam structure allows high-power LEDs to be cooled effectively without adding excessive weight, enabling improved light output.
3Ease of manufacture
If conventional separate LED and driver electronics mounting is used, then manufacturing is simplified, but device size and weight increase
Solution Approach 1:
The patent merges the LED mounting and driver electronics mounting onto a single circuit board, consolidating multiple components into one integrated platform. This integration reduces the overall fixture weight and size while maintaining ease of manufacture through standardized PCB fabrication processes.
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 achieves double the light output of conventional designs while reducing weight by 20%, providing a significantly more powerful and efficient lighting solution for drones without increasing size or weight.
Implementation Method 1
The most efficient light engines are LED based. But LEDs are still less than 50% efficient at converting electrical power (or wattage) to visible light. The rest of that power is dumped into heat that must be removed from the fixture for it to continue to operate without burning out.
Implementation Method 2
Managing that heat requires heat sinks typically consisting of machined, extruded, die cast or stamped metal fins or pins attached to a metal plate that has the circuit board with the LEDs on one side and the fins for dissipating the heat on the opposite side.
Implementation Method 3
The most efficient light engines are LED based. But LEDs are still less than 50% efficient at converting electrical power (or wattage) to visible light.
Data Source
AI summary
An LED drone light of high power and very light weight has an LED circuit board cooled by a foamed metal matrix of copper or aluminum. Preferably bonded to a disc or puck which is thermally bonded to the back of the PCB, the foamed metal matrix can be cooled by a small fan attached to the light's housing.