MCPCB Cross-Flow Heat Sink Coupling for Passive LED Cooling
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Solution Overview
Problem
Conventional LED fixtures in greenhouses face inefficiencies in heat dissipation due to minimal air movement, limiting their power consumption and productivity, as traditional linear heat sinks rely primarily on convection and radiation, which are insufficient for high-powered LEDs.
Innovation Solution
A cross-flow thermal management system using a metal core PCB (MCPCB) base positioned below exposed fins with a series of folded or extruded aluminum fins, creating additional air flow and increasing the surface area for heat dissipation, while minimizing thermal resistance and air bubble formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional linear heat sinks with wings extending parallel to the central axis are used, then the fixture structure is simple, but heat dissipation efficiency is insufficient due to minimal air movement in the middle of the fixture
Solution Approach 1:
The patent transitions from traditional linear heat sinks with wings extending parallel to the central axis to a cross-flow heat sink configuration where fins extend perpendicular to the central axis. This dimensional change allows air to flow across the fins from the sides, creating effective convection currents that significantly improve heat dissipation efficiency by utilizing the lateral dimension for air movement rather than relying on minimal central air flow.
2Productivity
If high powered lights are used to supplement natural light, then plant growth is improved, but heat generation increases requiring larger fixtures that block more sunlight
Solution Approach 1:
The patent extracts the heat dissipation function from the main fixture body by implementing a dedicated cross-flow heat sink structure with exposed fins that extend beyond the fixture boundaries. This allows heat to be dissipated externally through the fins, enabling the use of high-powered LEDs without requiring proportionally larger fixture enclosures, thus maintaining sunlight transmission while supporting higher productivity.
3Temperature
If active cooling fans are used in LED fixtures, then heat dissipation is improved, but the fans quickly clog with dirt and bugs in greenhouse environments becoming inoperable
Solution Approach 1:
The patent implements a passive cross-flow heat dissipation system that utilizes natural convection currents created by the cross-flow fin configuration. The system serves itself by allowing air to enter through openings in the fixture housing, flow across the exposed fins, and exit through upper openings, creating continuous cooling without requiring active mechanical components like fans. This eliminates the reliability issue of fan clogging while maintaining effective heat dissipation.
4Use of energy by moving object
If conventional LED fixtures are suspended with minimal air movement, then installation is simple, but heat dissipation is severely limited reducing power consumption capability
Solution Approach 1:
The patent resolves the contradiction between simple suspension installation and effective heat dissipation by implementing a cross-flow heat sink where fins extend perpendicular to the central axis with exposed surfaces on multiple sides. This dimensional configuration allows air to access the fins from lateral directions rather than requiring vertical air movement, enabling effective heat dissipation in suspended installations with minimal air movement while supporting higher power consumption capabilities.
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 system effectively dissipates heat through passive cross-flow, allowing for higher power consumption in LED fixtures by enhancing air flow and reducing thermal resistance, thus improving the efficiency and reliability of LED lighting in greenhouse environments.
Implementation Method 1
Heat generated through conventional LED fixtures may dissipate based on convection, conduction or radiation. However, due to LED fixtures being suspended, there is minimal heat dissipation via conduction. Radiation is a function of the fixture temperature and may be significant, and convection is the primary method to dissipate heat.
Implementation Method 2
A cross-flow thermal management system using a metal core PCB (MCPCB) base positioned below exposed fins with a series of folded or extruded aluminum fins, creating additional air flow and increasing the surface area for heat dissipation, while minimizing thermal resistance
Data Source
AI summary
Embodiments may utilize a series of exposed fins, which increase the surface area of the heat sink creating additional air flow. As hotter air rises within the system, cooler is drawn into the heatsink. The fins may be exposed on both sides of the longitudinal axis, allowing cooler air to be drawn towards the longitudinal axis above the heatsink and flow upward. This process may cool the fins. Additionally, the spacing between the fins may have to be wide enough to allow for air to freely enter the heatsink.