Heat Pipe Thermal Management for LED Light Units

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Solution Overview

Problem

High heat concentration in LED light units due to large numbers of LEDs packed in small spaces leads to reduced lifespan and maintenance challenges, especially in harsh environments like radio transmission towers and wind turbine generators.

Innovation Solution

The use of heat pipes and thermally conductive support plates with integrated heat collectors and evaporative cooling mechanisms to efficiently dissipate heat away from LEDs, minimizing thermal interfaces and maximizing heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Illumination intensity

If a large number of LEDs are packed in a small space to achieve high light output, then illumination intensity is improved, but heat concentration increases leading to reduced LED lifespan

Engineering Contradiction:

Improvelight outputVSAvoidheat concentration

Core Design Contradiction:

Illumination intensityVSTemperature

Solution Approach 1:

The heat dissipation system is segmented into multiple heat pipes distributed across the support plate, each independently managing heat from specific LED regions. This segmentation allows efficient heat distribution across multiple pathways, preventing heat concentration while maintaining high LED density for high light output.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Heat pipes serve as intermediary thermal transfer devices between the LED heat sources and the external environment. These heat pipes conduct heat away from the LED junctions through phase change mechanisms, effectively mediating the thermal management without requiring direct thermal contact between LEDs and the support structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If LEDs are positioned in hard-to-reach locations such as radio transmission towers, then adaptability is improved, but ease of repair deteriorates

Engineering Contradiction:

Improvelocation flexibilityVSAvoidmaintenance accessibility

Core Design Contradiction:

Adaptability or versatilityVSEase of repair

Solution Approach 1:

The LED array is designed as a modular, replaceable unit mounted on the support plate. When LEDs fail in hard-to-reach locations, the entire LED array can be quickly replaced as a single module rather than individually servicing each LED, reducing maintenance complexity and time for remote installations.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The support plate structure serves multiple functions: it provides mechanical mounting for the LED array, acts as a thermal management system through integrated heat pipes, and enables quick replacement of the entire LED module. This multi-functionality reduces the need for separate maintenance operations in remote locations.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Temperature

If thermally conductive materials are used to maximize heat transfer, then heat dissipation is improved, but device complexity increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidthermal interface complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The support plate combines structural support and thermal management functions into a single integrated component. Heat pipes are embedded within or attached to the support plate structure, merging the mechanical mounting function with the thermal conduction function, thereby reducing the number of separate thermal interface components needed.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

Heat pipes utilize phase transition (liquid to vapor and back) of the working fluid inside the heat pipe to transfer heat efficiently. This phase change mechanism provides high thermal conductivity without requiring complex active cooling systems or multiple thermal interface materials, simplifying the overall thermal management design.

Inventive Principle:

Principle #36Phase transitions

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

Extends the lifespan of LEDs by effectively managing heat dissipation, reducing maintenance needs, and ensuring reliable operation in demanding conditions.

Implementation Method 1

at least one heat pipe coupled to said LED board

Methodology Applied

Scientific EffectHeat pipe: Heat Pipe

Implementation Method 2

heat pipes and thermally conductive support plates with integrated heat collectors

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

evaporative cooling mechanisms to efficiently dissipate heat away from LEDs

Methodology Applied

Scientific EffectEvaporative cooling: Evaporative Cooler

Implementation Method 4

evaporative cooling mechanisms

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentUS9578716B2Apparatus for using heat pipes in controlling temperature of an LED light unit

Publication Date: 2017.02.21 DIALIGHT CORP

AI summary

A light emitting diode (LED) light unit is disclosed. For example, the LED light unit includes at least one support plate having one or more inner openings. At least one LED array may be coupled to an LED board. The LED light unit also includes at least one heat pipe coupled to the LED board, wherein said LED board is coupled to the at least one support plate.