LED Module Liquid Cooled Reflector Thermal Management
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Solution Overview
Problem
High intensity LED modules used for UV curing in the printing industry face challenges in thermal energy management due to heat buildup, which can damage components and cause safety hazards, and require improved designs for efficient cooling.
Innovation Solution
The design incorporates a fluid cooling passageway within the LED reflector extrusion, including an orifice bushing to restrict coolant flow and prevent starvation, coupled with a heat exchanger and insulated end caps to maintain a stable coolant flow, effectively lowering the operating temperature of the reflector portion to a range of 70°F to 80°F.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high intensity LED devices are used to produce UV radiation, then curing rate is improved, but heat buildup increases causing damage to components and safety hazards
Solution Approach 1:
The patent extracts the cooling function from the overall LED module design by incorporating a separate coolant circulation system with cooling channels. This allows the heat removal function to be independently optimized without compromising the high-intensity UV radiation capability of the LED array.
Solution Approach 2:
The patent introduces coolant as an intermediary substance between the heat-generating LED devices and the surrounding environment. The coolant absorbs excess heat through controlled circulation channels, preventing direct thermal damage to components while maintaining the high curing rate capability.
2Illumination intensity
If high density packaging of LED devices is used to focus high levels of specific wavelength light, then UV radiation intensity is improved, but heat generation increases
Solution Approach 1:
The patent segments the LED module into distinct functional zones: a high-density LED array region for UV generation, integrated cooling channels for heat removal, and reflective surfaces for light focusing. This segmentation allows each component to be optimized independently - high density packaging for illumination intensity while cooling channels manage the resulting heat generation.
3Temperature
If coolant flow is increased through the reflector portion, then cooling effectiveness is improved, but coolant starvation occurs elsewhere in the LED module
Solution Approach 1:
The patent applies local quality by providing differentiated cooling pathways - the reflector portion receives targeted cooling through specific channels optimized for its thermal characteristics, while other LED components have dedicated cooling paths. This ensures each region receives appropriate coolant flow without causing starvation elsewhere in the module.
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 solution effectively manages heat and maintains a stable operating temperature, preventing damage to LED components and ensuring safe handling, while maintaining efficient UV radiation focusing capabilities.
Implementation Method 1
coolant flow through the reflector portion to a temperature within the range of 70°F to 80°F
Implementation Method 2
An orifice bushing can be disposed within a coolant passageway defined in the first end cap to restrict coolant flow through the reflector portion to preclude starvation of coolant flow elsewhere in the LED module
Implementation Method 3
The design incorporates a fluid cooling passageway within the LED reflector extrusion, including an orifice bushing to restrict coolant flow and prevent starvation, coupled with a heat exchanger and insulated end caps
Implementation Method 4
coupled with a heat exchanger and insulated end caps to maintain a stable coolant flow
Data Source
Figure 1~2
Figure 3
AI summary
A light emitting diode (LED) module includes a first end cap, a second end cap and a reflector portion. The reflector portion extends longitudinally between the first end cap and the second end cap. The reflector portion includes a coolant passageway defined longitudinally through the reflector portion and is fluidically coupled to the first end cap and the second end cap. An LED package is disposed adjacent to the reflector portion. An orifice bushing can be disposed within a coolant passage defined in the first end cap to restrict coolant flow through the reflector portion to preclude starvation of coolant flow elsewhere in the LED module.