LED Luminaire Cooling via Remote Fluid Loop
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Solution Overview
Problem
Existing cooling systems for high-powered LED arrays in automated luminaires are inefficient, noisy, and constrained by the need for large heat sinks that conflict with optical and physical requirements, with heat dissipation occurring close to the LEDs, limiting design flexibility and efficiency.
Innovation Solution
A cooling system utilizing a thermal transmission liquid and active pump to transfer heat from the LEDs to a remotely located heat exchanger, allowing for efficient heat dissipation away from the LEDs, with optional phase change heat pump systems and active control using feedback from temperature sensors to manage fan and pump speeds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If large heat sinks are used for LED cooling, then heat dissipation efficiency is improved, but the luminaire size and design flexibility are reduced
Solution Approach 1:
The cooling system is divided into separate functional components: a compact heat sink near the LEDs, a thermal transmission liquid circulation system, and a remote heat exchanger. This segmentation allows the heat dissipation function to be distributed, enabling efficient cooling without requiring a single large heat sink that would constrain the luminaire design.
Solution Approach 2:
A thermal transmission liquid is introduced as an intermediary medium to transfer heat from the LEDs to a remotely located heat exchanger. This liquid circulation system enables heat dissipation to occur at a distance from the light source, eliminating the need for large heat sinks adjacent to the LEDs and thereby increasing design flexibility.
2Loss of energy
If active cooling systems with fans are used, then heat dissipation is improved, but noise levels increase
Solution Approach 1:
The system replaces the mechanical fan-based active cooling with a thermally-driven liquid circulation system. The thermal transmission liquid is pumped through the system, providing active cooling without the high-speed rotating fans that generate significant noise, thereby reducing harmful noise output while maintaining effective heat dissipation.
3Temperature
If heat dissipation occurs close to the LEDs, then cooling effectiveness is improved, but design flexibility and orientation capability are reduced
Solution Approach 1:
The thermal transmission liquid serves as a mobile intermediary that can transport heat away from the LEDs to a remotely positioned heat exchanger. This remote heat exchanger can be optimally positioned for heat dissipation without being constrained by the need to be adjacent to the LEDs, thereby maintaining cooling effectiveness while enabling the luminaire to operate in various orientations and configurations.
Solution Approach 2:
The heat dissipation function is moved from the spatial dimension immediately surrounding the LEDs to a different spatial location via liquid circulation. This dimensional separation allows the heat exchanger to be positioned in an optimal location for thermal management without being constrained by the optical and mechanical requirements of the LED assembly, thereby enhancing orientation capability.
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 provides improved cooling efficiency, reduced noise, and increased design flexibility by allowing heat dissipation at a distant point from the LEDs, enabling compact and effective cooling systems that can operate in any orientation and adapt to changing light output demands.
Implementation Method 1
heat conducting substrate board which, in turn, is mounted to a heat exchanger. Heat from the LEDs passes through the substrate board into the heat exchanger
Implementation Method 2
Pump circulates the thermal transmission liquid, as indicated by arrows, around pipes to second heat exchanger
Implementation Method 3
second heat exchanger which is being cooled by fan and air flow
Implementation Method 4
second heat exchanger which is being cooled by fan and air flow
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Described is an improved cooling system for luminaires. More specifically a cooling system where the heat is carried away from the heat generation light source via a first heat exchanger to a second separated heat exchanger via a contained fluid loop.