Heat-Dissipating Lighting Panel With Recycled Aluminum Core
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Solution Overview
Problem
LEDs in illuminated panels face heat-related issues such as thermal runaway, material degradation, and reduced efficiency due to inadequate heat dissipation, which limits their performance and lifespan, and existing solutions do not effectively address these challenges while also failing to utilize sustainable materials.
Innovation Solution
A lighted heat dissipating panel constructed from a combination of recycled expanded aluminum and glass-carbon composite materials, with embedded LEDs, where heat is transferred from the LEDs to a radiating surface and through mounting points to an external structure, using soy-based urethane for reduced environmental impact and increased stiffness and moldability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If LEDs are used in illuminated panels, then energy efficiency and longevity are improved, but heat dissipation becomes inadequate leading to thermal runaway and reduced reliability
Solution Approach 1:
The patent extracts the heat dissipation function from the traditional integrated LED mounting structure by introducing a separate aluminum heat sink with fins. This heat sink is thermally coupled to the LED but physically distinct, allowing efficient heat removal while maintaining LED operational integrity and preventing thermal runaway.
Solution Approach 2:
The patent introduces a thermal interface material or mounting structure as an intermediary between the LED and the aluminum heat sink. This intermediary ensures optimal thermal contact and heat transfer from the LED junction to the heat dissipation structure, effectively managing the temperature gradient and improving LED reliability.
2Ease of manufacture
If traditional illuminated panels are used, then construction is simpler, but sustainable material utilization is insufficient
Solution Approach 1:
The patent employs composite materials including aluminum for the heat sink, recyclable plastics for panel components, and potentially bio-based materials for mounting structures. These composite constructions maintain ease of manufacturing through modular assembly while significantly improving sustainable material utilization and reducing environmental impact compared to traditional homogeneous materials.
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 effectively dissipates heat from LEDs, enhancing their lumen output and reliability, while being environmentally friendly and suitable for various applications, including architectural and shelving uses, with the added benefit of reduced carbon footprint and energy efficiency.
Implementation Method 1
heat is transferred from the LEDs to the heat dissipating surface... heat is conducted away from the light source or sources... heat is transferred from the LEDs to a radiating surface and through mounting points to an external structure
Implementation Method 2
heat dissipating panel comprised of embedded light sources... heat is transferred from the LEDs to the heat dissipating surface... radiating surface
Data Source
AI summary
A lighted heat dissipating panel made of sustainable renewable materials such as recycled aluminum and soy-based urethane, for use in architectural or shelving applications. The panel may be flat, rectangular, curvilinear, or of varying cross section so as to include any three-dimensional shape as desired. Lightweight materials such as carbon fiber, fiberglass, resin, soy-based urethane, and similar materials are used in combination with thermally conductive structural materials, such as expanded aluminum honeycomb, preferably fabricated from recycled aluminum, to provide a stiff, lightweight, machinable, moldable, and thermally conductive panel for use with lighting elements. Lighting elements are housed within the panel, providing illumination as desired. Heat is transferred from the lighting elements through the panel to the supporting structure and radiated from the panel itself, providing cooling effect for the lighting elements, reducing the temperature in the immediate vicinity of the lighting elements and providing for longer lighting element life.