Segmented Cooling Wings for LED Light Heat Dissipation
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Solution Overview
Problem
Existing cooling systems for electrical components, such as heat sinks, face challenges including high weight, noise due to vibration, complex manufacturing processes, and limited design flexibility, which increase costs and hinder efficient heat dissipation.
Innovation Solution
A cooling system comprising a contact element with multiple cooling wings that can be easily assembled and connected, allowing for flexible design and efficient heat transfer, using thermally conductive materials like aluminum or thermally conductive plastics, with a mandrel and retaining ring mechanism for secure attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat sinks are made from extruded or drawn profiles of light metal, then cooling effect is achieved, but weight is relatively high and manufacturing complexity increases
Solution Approach 1:
The cooling system is divided into separate modular components: a contact element and multiple cooling wings that can be attached independently. This segmentation allows each component to be optimized separately and reduces overall weight compared to monolithic profile-based heat sinks.
Solution Approach 2:
The patent transitions from traditional three-dimensional extruded profiles to a two-dimensional planar structure where cooling wings are attached to a contact element. This dimensional simplification reduces material usage and weight while maintaining effective heat dissipation surface area.
2Ease of operation
If cooling fins are cut or reworked, then mounting surfaces can be provided, but vibration causes noise and machining tolerances are difficult to maintain
Solution Approach 1:
Mounting surfaces and attachment features are pre-integrated into the cooling wing design during manufacturing. The cooling wings include built-in attachment mechanisms that eliminate the need for subsequent cutting or reworking operations, preventing vibration-induced noise from the outset.
Solution Approach 2:
The patent separates the mounting function from the cooling function by integrating attachment features directly into the cooling wing structure. This extraction of the machining operation eliminates the source of vibration and noise that occurs during cutting or reworking of traditional heat sink profiles.
3Weight of moving object
If heat pipes are used to reduce weight, then weight is lower with comparable cooling effect, but the structure becomes bulky and design flexibility is limited
Solution Approach 1:
The cooling system is segmented into a contact element and separate cooling wings that can be independently designed and configured. This modular approach provides design flexibility to adapt to various lamp geometries and heat dissipation requirements without the bulkiness of traditional heat pipe structures.
Solution Approach 2:
The patent employs a two-dimensional planar arrangement of cooling wings attached to a contact element, replacing the three-dimensional bulky structure of heat pipes. This dimensional change achieves weight reduction while maintaining design flexibility for compact lamp configurations.
4Temperature
If multiple thin-walled metal sheets are stacked to form heat sink, then cooling surface is increased, but pressure blocks add weight and structure becomes complex
Solution Approach 1:
The patent combines multiple cooling surfaces into integrated cooling wings that are attached to a single contact element. This merging eliminates the need for separate pressure blocks to hold multiple sheets together, reducing weight and structural complexity while maintaining increased cooling surface area.
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
The system achieves effective heat dissipation with reduced weight, noise, and manufacturing complexity, enabling cost-efficient implementation in various designs, particularly suitable for LED lighting applications.
Implementation Method 1
They are used to dissipate heat loss from the component and to transfer the dissipated heat to the ambient air
Implementation Method 2
The natural convection can, for example, be supported by fans
Data Source
Figure 1a~1c
Figure 2a~2d
Figure 3a~3c
AI summary
The system (100) has a cooling module (101) transferring discharged heat to surrounding and comprising a contact element (103). The contact element is in contact with an electric component. The cooling module comprises electrode radiators (1010), which are connected with the contact element. The electrode radiators are arranged with respect to a middle axis (A) of the contact element in a fan-shaped manner. The electrode radiators define a cylindrical casing of the system, and have uniform material strength. The contact element comprises a contact surface. The light is provided with a light unit and/or an LED module. An independent claim is also included for a method for manufacturing a cooling system.