LED Vehicle Lighting Thermal Management via Integrated Radiating Body
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Solution Overview
Problem
Existing vehicle lighting devices using LEDs are complex, heavy, and bulky due to the need for metal radiating elements for heat dissipation, and face challenges in efficiently transmitting heat outside while preventing humidity and condensation.
Innovation Solution
A lighting device with a plastic body housing LEDs on a printed circuit in direct thermal contact, utilizing a high thermal conductivity central portion and appendages to dissipate heat directly to the outside, and optionally incorporating a metal layer and depressed seats to enhance heat transfer and distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a metal radiating element is used for heat dissipation, then heat dissipation effectiveness is improved, but device complexity, weight, and volume increase
Solution Approach 1:
The patent merges the radiating element with the plastic body by integrating a metal layer directly into the plastic structure. The metal layer is formed within the plastic body through co-molding or insertion molding processes, creating a unified component that eliminates the need for separate metal radiating elements and their associated mounting hardware.
Solution Approach 2:
The patent employs composite materials by combining plastic and metal layers within the same body structure. The plastic body contains an integrated metal layer that provides thermal conduction pathways while maintaining the overall plastic construction, achieving both thermal management and structural functionality in a single composite component.
2Temperature
If a metal radiating element is used for heat dissipation, then heat dissipation effectiveness is improved, but device weight increases
Solution Approach 1:
The patent merges the radiating element with the plastic body by integrating a metal layer directly into the plastic structure. The metal layer is formed within the plastic body through co-molding or insertion molding processes, creating a unified component that eliminates the need for separate metal radiating elements and their associated mounting hardware.
Solution Approach 2:
The patent employs composite materials by combining plastic and metal layers within the same body structure. The plastic body contains an integrated metal layer that provides thermal conduction pathways while maintaining the overall plastic construction, achieving both thermal management and structural functionality in a single composite component.
3Temperature
If a metal radiating element is used for heat dissipation, then heat dissipation effectiveness is improved, but device volume increases
Solution Approach 1:
The patent merges the radiating element with the plastic body by integrating a metal layer directly into the plastic structure. The metal layer is formed within the plastic body through co-molding or insertion molding processes, creating a unified component that eliminates the need for separate metal radiating elements and their associated mounting hardware.
Solution Approach 2:
The patent employs composite materials by combining plastic and metal layers within the same body structure. The plastic body contains an integrated metal layer that provides thermal conduction pathways while maintaining the overall plastic construction, achieving both thermal management and structural functionality in a single composite component.
4Temperature
If air venting devices are used to transmit heat outside, then heat dissipation is improved, but device complexity increases
Solution Approach 1:
The patent merges the radiating element with the plastic body by integrating a metal layer directly into the plastic structure. The metal layer is formed within the plastic body through co-molding or insertion molding processes, creating a unified component that eliminates the need for separate metal radiating elements and their associated mounting hardware.
5Temperature
If air venting devices are used to transmit heat outside, then heat dissipation is improved, but humidity and condensation control becomes more difficult
Solution Approach 1:
The patent merges the radiating element with the plastic body by integrating a metal layer directly into the plastic structure. The metal layer is formed within the plastic body through co-molding or insertion molding processes, creating a unified component that eliminates the need for separate metal radiating elements and their associated mounting hardware.
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 results in a simpler, lighter, and cost-effective lighting device with effective heat dissipation, reducing thermal resistance and maintaining structural integrity while preventing humidity and condensation.
Implementation Method 1
a printed circuit arranged in thermal contact with the plastic body, or a portion thereof, which forms a radiating element to dissipate the heat generated by said LEDs to the outside
Implementation Method 2
the plastic body, or a portion thereof, which forms a radiating element to dissipate the heat generated by said LEDs to the outside
Data Source
Figure 1
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AI summary
A lighting device for vehicles, in particular motor vehicles, comprising a body (2) made of plastic material and defining a front opening (3) closed by a transparent element (5) and housing a light source (7) formed by a plurality of LED diodes (9) arranged on a printed circuit (12) which forms the electro-thermal connection of the LEDs (9). The printed circuit (12) is arranged in thermal contact with the plastic body or a portion (13) of the body, which forms a radiating element dissipating the heat generated by the LED sources (9) to the outside.