Automotive Headlight Optical Module Cooling with Air Deflectors
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Solution Overview
Problem
Automotive headlamp optical modules face challenges in cooling high-power LEDs without increasing the module's size and mass, which is crucial for efficient heat dissipation and easy installation within limited spaces.
Innovation Solution
A cooling device with a heat conductor and deflectors that channel cold air towards a finned heat sink, allowing for efficient convective heat exchange without mechanical contact, enabling effective heat dissipation while maintaining the module's mobility and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the surface area of the finned heat sink is increased to improve heat dissipation, then the cooling efficiency is improved, but the mass and overall size of the optical module increases
Solution Approach 1:
The patent applies forced convection using a fan to drive air flow through the heat sink fins, replacing reliance on natural convection. This allows effective heat dissipation with a more compact heat sink design, reducing both size and mass while maintaining cooling efficiency.
Solution Approach 2:
The patent introduces a movable fan that can be positioned at different locations within the housing to optimize air flow dynamics. The fan creates controlled dynamic air flow patterns that enhance heat exchange efficiency without requiring excessive heat sink surface area.
2Temperature
If the surface area of the finned heat sink is increased to improve heat dissipation, then the cooling efficiency is improved, but the overall size of the optical module increases
Solution Approach 1:
By implementing forced air convection through a fan, the system achieves superior heat dissipation performance in a more compact volume. The controlled air flow maximizes heat exchange efficiency without requiring excessive heat sink surface area, thus reducing overall module size.
Solution Approach 2:
The fan creates dynamic air circulation patterns that enhance heat transfer coefficients, allowing effective cooling in a reduced volume. The air flow dynamics compensate for the reduced heat sink surface area, maintaining cooling efficiency while shrinking module dimensions.
3Device complexity
If natural air flow is used for cooling, then the device complexity is reduced, but the heat dissipation capacity is insufficient for high-power LEDs
Solution Approach 1:
The patent introduces a fan-driven forced convection system that provides sufficient heat dissipation capacity for high-power LEDs. The fan creates controlled air flow through the heat sink, significantly enhancing heat transfer rates compared to natural convection, while adding only moderate system complexity.
4Temperature
If a fan is used to induce forced air flow for cooling, then the heat dissipation capacity is improved, but the device complexity increases
Solution Approach 1:
The patent integrates the fan directly into the housing structure, merging the cooling function with the existing housing components. This integration approach reduces overall system complexity by eliminating separate cooling housing structures and simplifying assembly, while maintaining effective forced convection cooling.
Solution Approach 2:
The housing structure serves multiple functions: it provides structural support, contains optical components, and acts as part of the cooling system by housing the fan and guiding air flow. This multi-functionality reduces the need for dedicated cooling components, thereby reducing overall system complexity.
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
This solution effectively cools high-power LEDs in headlamps by optimizing heat exchange through natural air flow, reducing the bulk and mass of the cooling system, and facilitating easy installation and operation.
Implementation Method 1
a first end of which constitutes a cold surface with respect to the surrounding air of the optical module... heat exchange between the flow of air and this surface of heat exchange
Implementation Method 2
a plurality of deflectors channeling a flow of cold air coming from said first end towards the heat exchange surface of the cooling member
Implementation Method 3
heat exchange by convection between this air flow and the heat exchange surface of a cooling member... optimization of the heat exchange between the finned heatsink heated by the LEDs and the air
Data Source
Figure 1~2
Figure 3~5
Figure 6~7
AI summary
The invention relates to a lighting and/or signaling device comprising at least one optical module (2) equipped with a cooling element (5), comprising at least one heat conductor (8) one end of which (9) is placed at a distance from the cooling element (5) and is provided with a plurality of deflectors (10) channeling a flow of cold air (F) towards the heat exchange surface (6) of the cooling element (5).