LED Heatsink With Integrated Refrigerant Paths

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Solution Overview

Problem

Commercially available LED-based heating apparatus are inefficient and costly due to limitations in cooling methods, such as air and water cooling, which cannot operate effectively below ambient temperatures without additional expenses, and existing refrigeration systems are bulky and expensive.

Innovation Solution

A heating apparatus comprising an LED array thermally coupled to a heatsink with refrigerant paths, where cooled refrigerant is passed through the heatsink to dissipate heat, maintaining the LEDs at lower temperatures and increasing their lifespan and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If air or water cooling methods are used for LEDs, then the cooling system is simple to implement, but the LEDs cannot operate effectively below ambient temperatures and additional cooling costs are required

Engineering Contradiction:

ImproveLED operating temperatureVSAvoidtemperature range capability

Core Design Contradiction:

TemperatureVSAdaptability or versatility

Solution Approach 1:

The patent changes the cooling parameter from ambient-temperature cooling (air/water) to sub-ambient temperature cooling using refrigerant. The refrigeration system enables the cooling medium to operate at temperatures below ambient, allowing LEDs to function effectively in extended temperature ranges and improving their operational efficiency and lifespan.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs a refrigeration system with refrigerant circulation (pneumatic/hydraulic approach) to achieve sub-ambient cooling. The refrigerant absorbs heat from the LEDs and is compressed and condensed externally, enabling effective cooling below ambient temperatures without the limitations of air or water cooling methods.

Inventive Principle:

Principle #29Pneumatics and hydraulics

2Duration of action of stationary object

If traditional refrigeration systems are used to cool LEDs below ambient temperatures, then LED lifespan and efficiency are improved, but the system becomes bulky and expensive

Engineering Contradiction:

ImproveLED lifespanVSAvoidcooling system size and cost

Core Design Contradiction:

Duration of action of stationary objectVSDevice complexity

Solution Approach 1:

The patent integrates the refrigerant paths directly within the heatsink structure (internal cooling channels), rather than using external refrigeration equipment. This dimensional integration reduces the overall system footprint and complexity while maintaining the sub-ambient cooling capability that extends LED lifespan.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The patent combines the heatsink and refrigerant circulation system into a single integrated unit. The refrigerant paths are embedded within the heatsink structure, merging the thermal management functions and reducing the need for separate bulky refrigeration components, thereby lowering system cost and complexity.

Inventive Principle:

Principle #5Merging (Combining)

3Power

If LEDs are operated at higher power output, then irradiance is increased, but LED lifespan decreases due to heat damage

Engineering Contradiction:

ImproveLED power outputVSAvoidLED lifespan

Core Design Contradiction:

PowerVSDuration of action of stationary object

Solution Approach 1:

The patent implements a feedback mechanism where the refrigeration system continuously removes heat generated by high-power LED operation. This active thermal feedback control maintains LEDs at optimal operating temperatures even at high power outputs, allowing sustained high irradiance without compromising lifespan.

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent converts the harmful heat generated by high-power LED operation into a manageable thermal load by capturing it through the refrigerant paths. The heat absorbed by the refrigerant is then dissipated externally, transforming the harmful thermal effect into a controlled cooling process that enables sustained high-power operation.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 solution extends the LED lifespan, reduces costs, and increases power output by effectively cooling LEDs below ambient temperatures, achieving higher irradiance without damaging the LEDs, and provides a more efficient and cost-effective cooling method compared to traditional air or water cooling systems.

Implementation Method 1

a heatsink (108) thermally coupled to the LED array (102)

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

wherein cooled refrigerant is passed through one or more refrigerant paths (110) in the heatsink (108)

Methodology Applied

Scientific EffectPhase change: Phase Change

Data Source

PatentEP3301999B1Light emitting diode heatsink

Publication Date: 2020.06.17 HP SCITEX LTD

Figure 1
Figure 2A~2D
Figure 3A~3B

AI summary

An example heating apparatus comprises a light emitting diode (LED) array comprising at least one LED to heat a target object. The heating apparatus further comprises a heatsink thermally coupled to the LED array to dissipate heat from the LED array. The heatsink comprises a refrigerant path including an input to and an output from the refrigerant path to pass cooled refrigerant therethrough.