Cooler of a light source with integrated cooling channels
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Solution Overview
Problem
Current coolers for motor vehicle lamps, especially those using thermally conductive plastics, face inefficiencies in heat dissipation and require complex designs, high material costs, and limited machining flexibility, which complicates the integration and replacement of light sources and cooling media.
Innovation Solution
A thermally conductive cooling monobloc with channels for cooling media supply, featuring a main channel with secondary channels that direct cooling media flow in parallel to the monobloc's longitudinal axis, and removable covers with inner and outer fins to enhance heat transfer and turbulence, allowing for easier replacement and integration of light sources and cooling media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If thermally conductive plastic material is used for the cooler, then design flexibility and ease of manufacture are improved, but thermal conductivity and heat dissipation efficiency deteriorate
Solution Approach 1:
The patent employs a composite structure combining thermally conductive plastic material with integrated cooling channels and fins. The plastic material provides design flexibility and ease of manufacture through compression molding, while the integrated cooling channels and fins enhance heat dissipation capability, creating a composite solution that balances manufacturability with thermal performance.
Solution Approach 2:
The patent introduces three-dimensional cooling channels and fins within the cooler structure. The cooling channels extend through the cooler body and the fins project outward, utilizing spatial dimensions to increase the cooling surface area and improve heat dissipation efficiency without compromising the ease of manufacture of the base plastic structure.
2Temperature
If aluminum material is used for the cooler, then thermal conductivity and heat dissipation efficiency are improved, but material cost and machining complexity increase
Solution Approach 1:
The patent substitutes expensive aluminum material with a more economical thermally conductive plastic material. While aluminum provides superior thermal conductivity, the plastic material offers a cost-effective alternative that can be manufactured through compression molding, reducing material costs and simplifying the manufacturing process while still achieving adequate heat dissipation through integrated cooling features.
Solution Approach 2:
The patent changes the material parameter from metal (aluminum) to plastic, fundamentally altering the manufacturing approach. This parameter change enables the use of compression molding instead of complex machining operations, significantly improving ease of manufacture and reducing costs, while the thermal performance is compensated through optimized cooling channel and fin design.
3Temperature
If complex cooler design is used, then heat dissipation capability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges the cooler structure with the light source holder into an integrated assembly. The cooler body, cooling channels, and mounting features are combined into a single thermally conductive plastic component manufactured through compression molding. This merging reduces device complexity by eliminating separate parts and assembly steps while maintaining effective heat dissipation capability through the integrated cooling features.
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 design significantly improves heat transfer efficiency from the light source to the cooling media, simplifies the cooler's design and production, and facilitates easier replacement of components while maintaining a compact and integral structure.
Implementation Method 1
arranged in a heat conductive cooling monobloc... fitted with cooling elements for dissipation of heat... significantly improves heat transfer efficiency from the light source to the cooling media
Implementation Method 2
channels for supply of the cooling media from the cooling media source to the cooling first side of the holder... improves heat transfer efficiency from the light source to the cooling media
Data Source
AI summary
A cooler of a light source, especially for a motor vehicle lamp, mounted in a light source holder (2) arranged in a thermally conductive cooling monobloc (11), is fitted with cooling elements for heat dissipation, and is equipped with channels (14, 17, 18, 19) for supplying cooling media from cooling media source (21) to the cooling first side (3) of the light source holder, the light source (1) being mounted on the opposite side (4) thereof. Main channel (14) is arranged with the cooling media flow direction in parallel to longitudinal axis of cooling monobloc, and at least one secondary channel leads into the main channel under the light source holder first side. The secondary channel can lead into the area under the light source holder first side. Secondary channels can at least partly comprise removable covers fitted with inner guiding and cooling fins (23, 24) and/or outer cooling fins.