LED Panel Air Flow Diverter for Photocatalytic Reactor Cooling
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Solution Overview
Problem
LEDs dissipate a significant portion of their energy as heat, leading to increased soldering point temperatures and reduced lifespan and efficiency, with existing heat dissipation methods like metal-based PCBs and active cooling solutions being inadequate.
Innovation Solution
An LED panel array design featuring air flow diverters on a second LED panel that redirects and passes air flow, minimizing pressure drop and enhancing heat dissipation through convection, with windows on both panels for airflow and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If metal-based PCBs with aluminum or copper layers are used to spread heat, then heat dissipation is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the heat dissipation function from the PCB structure itself and separates it into a dedicated heat sink component. The PCB uses simple copper traces for electrical connection, while a separate heat sink with fins handles thermal management, simplifying the PCB design while maintaining effective heat dissipation.
Solution Approach 2:
The invention introduces a thermal paste as an intermediary substance between the LED and the heat sink. This thermal paste improves heat transfer efficiency by filling microscopic gaps and providing a thermal conduction path, enabling effective heat dissipation without requiring direct metal-to-metal contact that would complicate the assembly.
2Temperature
If active cooling solutions such as fans are used, then heat dissipation is improved, but reliability decreases due to different life expectancy
Solution Approach 1:
The invention implements passive heat dissipation through naturally convecting air flow that cools the LEDs without requiring external power or moving parts. The vertical fin structure creates natural air circulation that carries heat away from the LED, making the system self-cooling and eliminating components with limited lifespans.
Solution Approach 2:
The invention replaces the mechanical fan-based active cooling system with a passive convection-based cooling system. By using vertically oriented fins that induce natural air flow, the system eliminates mechanical moving parts while maintaining effective heat dissipation, thereby improving reliability.
3Productivity
If LEDs operate at high power, then productivity and light output are improved, but temperature increases reducing efficiency and lifespan
Solution Approach 1:
The invention transitions from planar heat dissipation to three-dimensional heat management by using vertically extending fins. This vertical dimension provides significantly increased surface area for heat transfer to the surrounding air, enabling high-power LED operation without excessive temperature rise that would reduce efficiency and lifespan.
Solution Approach 2:
The invention changes the physical parameters of the heat dissipation system by using vertically oriented fins with specific spacing and dimensions. This configuration optimizes natural convection current patterns and maximizes heat transfer surface area, allowing the LED to operate at high power while maintaining temperatures that preserve efficiency and lifespan.
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 reduces the temperature of the second LED panel by 7% to 9% compared to prior art designs, improving the operational efficiency and lifespan of LEDs by effective heat dissipation.
Implementation Method 1
enhancing heat dissipation through convection
Implementation Method 2
heat dissipation through convection
Implementation Method 3
heat transfer between the thermal unit and the metal foam
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A light-emitting diode (LED) panel (14) includes a support (15) having a first side, a second side opposite the first side, and a window (16) that extends from the first side to the second side. An LED (17) is affixed to the first side. An air-flow diverter (18) is affixed to the second side. The diverter includes an angled portion (18a), wherein the angled portion extends over a window portion that is less than all of the window (16).