Thermal Transport Layer for LED Heat Dissipation

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Solution Overview

Problem

Commercial LEDs face heat dissipation challenges, which affect their lifetime and luminous flux, particularly in applications where increased operating temperature alters the emitted color or wavelength, and existing thermal management systems often increase module size and generate noise.

Innovation Solution

A light-emitting article with a thermal transport layer made from thermally conductive materials, such as inorganic or organic composites, that secures to the display layer to effectively dissipate heat generated by the light-emitting device, maintaining thermal uniformity and reducing distortions caused by refractive index mismatches and thermal expansion differences.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If a heat sink with fan or piezoelectric jet actuator is used to dissipate heat, then heat dissipation capability is improved, but device size and footprint increase

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidmodule footprint

Core Design Contradiction:

TemperatureVSArea of stationary object

Solution Approach 1:

The patent combines multiple thermal management functions into a single integrated layer. The thermal transport layer integrates heat conduction, heat distribution, and heat dissipation functions that were previously separated across multiple components (heat sink, fan, or piezoelectric actuator), thereby reducing the overall module footprint while maintaining effective heat dissipation capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The thermal transport layer serves multiple functions simultaneously: it conducts heat away from the LED, distributes heat uniformly across the layer, and provides a pathway for heat dissipation. This multi-functionality replaces the need for separate specialized components, reducing the required space while achieving comprehensive thermal management.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Temperature

If a heat sink with fan or piezoelectric jet actuator is used to dissipate heat, then heat dissipation capability is improved, but noise generation increases

Engineering Contradiction:

Improveheat dissipation capabilityVSAvoidnoise

Core Design Contradiction:

TemperatureVSObject-generated harmful factors

Solution Approach 1:

The patent replaces active mechanical cooling systems (fans or piezoelectric jet actuators) with a passive thermal transport layer that relies on thermal conduction and natural heat dissipation mechanisms. This substitution eliminates the mechanical components that generate noise while maintaining effective heat dissipation through the integrated thermal management layer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Temperature

If thermal management is achieved by controlling junction temperature and forward current, then thermal uniformity is improved, but device complexity increases

Engineering Contradiction:

Improvethermal uniformityVSAvoidcontrol system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The thermal transport layer provides passive thermal management that automatically maintains thermal uniformity without requiring active control systems. The layer's inherent thermal conduction properties and geometric design enable it to self-regulate temperature distribution, eliminating the need for complex control mechanisms while achieving uniform thermal conditions.

Inventive Principle:

Principle #25Self-service

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 thermal transport layer efficiently transports heat away from the light-emitting device, maintaining performance and reducing distortions, while being flexible and transparent to match the display layer's properties, thus enhancing the LED's operational lifespan and luminous flux without increasing module size or generating noise.

Implementation Method 1

The thermal transport layer may include a thermally conductive material that can transport heat generated by the light-emitting device away from the light-emitting device

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS8058802B2Thermal management article and method

Publication Date: 2011.11.15 EDISON INNOVATIONS LLC

AI summary

An article includes a display layer having an outward facing surface and an inward facing surface. The display layer includes a light-emitting device that generates heat and light during use. A thermal transport layer may be secured to the display layer. The thermal transport layer may include a thermally conductive material that can transport heat generated by the light-emitting device away from the light-emitting device.