Heat Sink Coating Patterning for LED Thermal Coupling
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Solution Overview
Problem
Existing heat sinks for solid state light sources face challenges in balancing heat dissipation and coupling efficiency, particularly in compact designs like those needed in the automotive industry, where anodized coatings can reduce shear strength and thermal transfer.
Innovation Solution
A method involving anodized coating on heat sinks with post-process laser ablation to precisely remove coating in specific areas, adjusting surface roughness and patterns for improved adhesion and thermal transfer, allowing for enhanced heat dissipation without increasing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the heat sink is coated with anodized coating to improve heat dissipation, then heat dissipation capability is improved, but adhesion and thermal transfer between the solid state light source and heat sink deteriorate
Solution Approach 1:
The patent applies different surface treatments to different regions of the heat sink: the mounting surface receives laser ablation to remove anodized coating and create a rough profile for improved adhesion, while other surfaces retain the anodized coating for heat dissipation. This local differentiation resolves the contradiction between heat dissipation and adhesion.
Solution Approach 2:
The heat sink surface is segmented into functional zones: a mounting region with removed anodized coating for light source attachment, and remaining regions with intact anodized coating for thermal management. This segmentation allows simultaneous optimization of both adhesion and heat dissipation properties.
2Temperature
If the size of the heat sink is increased to improve heat dissipation, then heat dissipation capability is improved, but the overall assembly size increases
Solution Approach 1:
The patent changes the surface parameters of the heat sink through laser ablation, creating a rough surface profile that enhances adhesion and thermal transfer efficiency. This allows the existing heat sink size to achieve better thermal performance without increasing dimensions.
Solution Approach 2:
The patent replaces the mechanical approach of increasing heat sink size with a surface treatment approach (laser ablation) to improve thermal performance. This substitution allows achieving better heat dissipation without increasing the physical dimensions of the assembly.
3Strength
If laser ablation is used to remove anodized coating for improving adhesion, then adhesion strength is improved, but production complexity increases
Solution Approach 1:
The laser ablation process serves multiple functions simultaneously: it removes the anodized coating to improve adhesion, creates a rough surface profile for enhanced mechanical interlocking, and prepares the surface for optimal thermal contact. This multi-functionality reduces the need for separate processing steps.
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 approach improves heat dissipation and adhesion of solid state light sources to heat sinks, ensuring secure mounting and efficient thermal transfer while minimizing production costs and maintaining the thermal benefits of anodized coatings.
Implementation Method 1
A portion of the coated surface can be treated via laser ablation for placing the solid state light source
Implementation Method 2
coating the heat sink, may adversely affect coupling of the solid state light source to the heat sink or thermal transfer from the solid state light source to the heat sink
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
According to aspects of the disclosed subject matter, a method of placing a solid state light source on a heat sink can include coating a surface of the heat sink with an anodized coating or an e-coating, for example. A portion of the coated surface can be treated via laser ablation for placing the solid state light source. Additionally, the laser ablation parameters can be adjusted to provide a predetermined roughness to the treated portion of the coated surface.