3D-Printed Headlight Heat Sink With Integrated Air Duct Cooling
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Solution Overview
Problem
Existing vehicle lights face challenges in optimizing cooling performance within limited installation space and construction geometry, particularly in motor vehicle headlights.
Innovation Solution
A vehicle light design featuring a 3D-printed heat sink with a one-piece construction, incorporating an air duct and flange for fan attachment, optimized air flow, and cooling structural elements, allowing for improved cooling efficiency and reduced weight.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If conventional heat sink designs with separate components are used, then manufacturing and assembly are straightforward, but cooling performance cannot be optimized within limited installation space
Solution Approach 1:
The patent combines the heat sink base body, air duct, and fan mounting flange into a single integrated component. This merging of previously separate parts into one 3D-printed unit enables optimized cooling performance within limited space while simplifying assembly procedures
Solution Approach 2:
The patent utilizes 3D printing technology to create complex three-dimensional structures that cannot be achieved with conventional manufacturing. The air duct features intricate pathways and the flange has optimized geometry for fan integration, allowing superior cooling performance in constrained spatial dimensions
2Weight of moving object
If traditional multi-component heat sink assemblies are used, then manufacturing is simple, but weight is higher
Solution Approach 1:
By integrating multiple components into a single 3D-printed heat sink assembly, the patent eliminates the need for separate manufacturing and assembly of individual parts. This results in weight reduction through material optimization and removal of unnecessary joints and fasteners
Solution Approach 2:
The patent employs 3D printing technology which fundamentally changes the manufacturing approach from conventional subtractive or assembly-based methods. This enables complex geometries with optimized material distribution, achieving weight reduction while maintaining structural integrity and cooling functionality
3Productivity
If air duct design does not optimize flow direction, then manufacturing is easier, but cooling efficiency decreases
Solution Approach 1:
The patent applies 3D printing to create air ducts with locally optimized geometries that vary along the flow path. The duct cross-section and wall thickness are specifically tailored at different locations to maximize cooling efficiency, with complex variations that would be impossible with conventional manufacturing
Solution Approach 2:
The air duct design utilizes full three-dimensional complexity with varying cross-sections, curved pathways, and integrated features that optimize air flow in multiple directions. This 3D geometric freedom enables superior cooling efficiency compared to simple two-dimensional duct designs
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
Enhances cooling performance, reduces weight by approximately 10%, and optimizes space utilization while maintaining efficient air flow and heat dissipation.
Implementation Method 1
a fan (5) fastened to the heat sink (4), wherein the flange (4b) encloses an air inlet opening (4d) opening into the air duct (4c) and being designed to receive an air flow (L) generated by the fan (5)
Implementation Method 2
a heat sink (4), wherein the heat sink (4) is attached flatly to the rear side (3b) of the circuit carrier (3)
Implementation Method 3
the air duct (4c) extends up to an air outlet opening (4e), wherein the heat sink (4) is formed in one piece from 3D printed material
Data Source
AI summary
Vehicle light (1), in particular motor vehicle headlight (6), comprising a number of light sources (2), a circuit carrier (3) having a front side (3a) and a rear side (3b), wherein the light sources (2) are arranged on the front side (3a) of the circuit carrier (3), a heat sink (4), wherein the heat sink (4) is attached flatly to the rear side (3b) of the circuit carrier (3), and a fan (5) fastened to the heat sink (4), wherein the heat sink (4) has a base body (4a) for flat contact with the rear side (3b) of the circuit carrier (3), a flange (4b) for receiving the fan (5), and an air duct (4c), wherein the flange (4b) encloses an air inlet opening (4d) opening into the air duct (4c), which is designed to receive an air flow (L) generated by the fan (5), wherein the air duct (4c) extends up to an air outlet opening (4e), wherein the heat sink (4) is formed in one piece from 3D-printed material.