LED Illumination Device Liquid Cooling Parallel Tracks
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Solution Overview
Problem
Existing LED illumination devices for high-intensity applications face challenges with heat dissipation, leading to reduced efficiency and shorter lifetimes due to large dimensions and weight, and liquid cooling systems that inefficiently transfer heat as the coolant absorbs heat along its path, resulting in higher operating temperatures.
Innovation Solution
The illumination device employs a liquid cooling system with a first heat exchanger and a heat transmission block made of thermally conductive material, featuring parallel cooling tracks that maintain coolant temperature uniformity, allowing efficient heat absorption and dissipation, thereby maintaining LED operating temperatures below 60°C and extending their lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If plate-like dissipators are used to dissipate heat from LEDs, then heat dissipation is improved, but the device dimensions and weight increase significantly
Solution Approach 1:
The patent employs a liquid cooling system with coolant circulating through channels in the heat sink to efficiently remove heat from LEDs. This hydraulic cooling approach provides superior heat dissipation performance compared to passive plate-like dissipators, enabling effective temperature control without requiring excessively large thermal mass structures.
Solution Approach 2:
The patent optimizes the heat sink structure by changing its geometric parameters and thermal conductivity properties. The heat sink features optimized fin structures and high-conductivity material distribution that enhance heat transfer efficiency, allowing compact dimensions while maintaining effective heat dissipation and keeping LED temperatures within operational limits.
2Illumination intensity
If multiple collimation lenses are arranged in front of LEDs to concentrate light intensity, then illumination intensity is improved, but the containment body dimensions increase
Solution Approach 1:
The patent integrates collimation lenses directly onto the LED chip structure or mounts them in tightly coupled positions immediately in front of the LED emitters. This nested arrangement minimizes the space required for optical components while maximizing light concentration efficiency, allowing high illumination intensity without proportionally increasing the containment body volume.
3Temperature
If a liquid cooling system with a single heat exchanger is used, then heat dissipation is improved, but the coolant temperature increases along the flow path reducing efficiency
Solution Approach 1:
The patent divides the cooling system into multiple heat exchangers arranged in parallel or series configurations, with each heat exchanger handling a portion of the thermal load. This segmentation allows the coolant to maintain more uniform temperature across different cooling zones, preventing excessive temperature rise in any single heat exchanger and maintaining consistent heat absorption efficiency throughout the system.
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 configuration enables the generation of high luminous flux with compact dimensions, ensuring high light efficiency and extended LED lifetime while maintaining a suitable operating temperature, allowing for a more efficient and cost-effective solution.
Implementation Method 1
a heat transmission block (28) made of thermally conductive material, featuring parallel cooling tracks (29) that maintain coolant temperature uniformity, allowing efficient heat absorption
Implementation Method 2
the cooling circuit comprises a first heat exchanger (15) arranged in the containment body (5) of the projector and adapted to transfer the heat generated by the light sources (4) to the coolant fluid that traverses it
Implementation Method 3
a pump (13) provided that is adapted to circulate the coolant fluid in the cooling circuit between the first heat exchanger (15) and the second heat exchanger (17)
Implementation Method 4
a second heat exchanger (17) intended to receive the coolant fluid coming from the first heat exchanger (15) in order to cool down the coolant fluid itself before it re-enters into the first heat exchanger (15)
Data Source
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AI summary
Illumination device which comprises multiple illumination modules (3), each provided with a corresponding group of light sources (4), in particular LEDs, and a liquid cooling plant (11), which is operatively associated with the light sources (4) in order to dissipate heat generated by the latter during the operation thereof. In particular, the cooling plant (11) is provided with a heat exchanger (15), which is thermally connected to the light sources (4) and comprises a manifold (20) provided with a passage channel (21) having an inlet branch (22) and an outlet branch (24), and at least one heat transmission block (28) made of thermally conductive material, which carries the illumination modules (3) mounted thereon and is provided with multiple cooling tracks (29) which are hydraulically connected, parallel to each other, to the inlet branch (22) and to the outlet branch (24) of the passage channel (21) of the manifold (20) and are each arranged at a respective illumination module (3) in order to transfer the heat generated by the light sources (4) of such illumination module (3) to the coolant fluid which traverses the cooling track (29).