Automotive LED Heat Sink with Selective Anodization
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Solution Overview
Problem
Existing heat transfer systems for automotive LED lighting modules are inefficient and costly, as they often require full anodization of heat sinks, which is complex and expensive, and do not adequately manage heat to prevent LED malfunction or destruction due to excessive heating.
Innovation Solution
A heat exchange system with a heat sink plate and heat transfer airfoils, where only the peripheral airfoils are anodized, and optionally an enveloping airfoil and a thin plastic coating are used to enhance heat transfer efficiency while maintaining cost-effectiveness, with the anodized airfoils positioned to maximize radiation emissivity and aesthetic appeal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If full anodization of heat sink airfoils is implemented, then heat transfer efficiency is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent applies local quality by anodizing only specific airfoils (first and last airfoils in each row, and airfoils in visible areas) rather than all airfoils uniformly. This selective anodization focuses the enhanced heat transfer properties where they are most needed for radiation and aesthetics, while leaving internal airfoils non-anodized to reduce manufacturing complexity and cost.
2Temperature
If full anodization of heat sink airfoils is implemented, then heat transfer efficiency is improved, but manufacturing cost increases
Solution Approach 1:
The patent reduces manufacturing cost by applying anodization only to specific airfoils that are visible or critical for heat transfer, rather than treating all airfoils. This selective approach maintains adequate heat transfer performance while significantly reducing the cost of the anodization process.
Solution Approach 2:
The patent applies partial action by anodizing only a subset of airfoils (peripheral and visible ones) rather than all airfoils. This partial treatment provides sufficient heat transfer enhancement and aesthetic improvement at a lower manufacturing cost compared to complete anodization.
3Temperature
If peripheral airfoils are anodized, then junction temperature is reduced significantly, but aesthetic appearance may be compromised
Solution Approach 1:
The patent resolves this contradiction by specifically anodizing the airfoils in visible areas and peripheral positions. This selective treatment ensures that aesthetic appearance is maintained in visible regions while achieving significant junction temperature reduction through the enhanced radiation from anodized surfaces.
Solution Approach 2:
The anodization process changes the color and surface properties of the airfoils, providing both aesthetic improvement and enhanced heat transfer through increased radiation emissivity. The patent leverages this color change to simultaneously address appearance and thermal performance.
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 significantly reduces the junction temperature of LEDs by 14.5°C compared to non-anodized systems and approaches the efficiency of fully anodized systems at a lower cost, while also improving the aesthetic and heat transfer performance.
Implementation Method 1
a heat exchange system for transferring heat away from the light source, the heat exchange system having a heat sink plate and plurality of heat transfer airfoils thermally connected to the heat sink plate
Implementation Method 2
The pair of anodized heat transfer airfoils are at peripheral portion encompassing the plurality of non-anodized airfoils of the heat exchange system
Implementation Method 3
The pair of anodized heat transfer airfoils are at peripheral portion encompassing the plurality of non-anodized airfoils of the heat exchange system
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The present invention relates to a lighting module for an automotive vehicle. The lighting module comprises a light source (10) for producing a light beam. Additionally, the lighting module includes a heat exchange system (100) for transferring heat away from the light source (10). The heat exchange system (100) is provided with a heat sink plate (11) and a plurality of heat transfer airfoils. The plurality of heat transfer airfoils forms two parts with. a plurality of non-anodized heat transfer airfoils (14) and a pair of anodized heat transfer airfoils (12). The airfoils are provided such that the pair of anodized heat transfer airfoils (12) is at peripheral portion encompassing the plurality of non-anodized airfoils (14) of the heat exchange system (100). The plurality of non-anodized airfoils (14) and pair of anodized heat transfer airfoils (12) are thermally connected to the heat sink plate (11) and transfer the heat away from the system.