Optical Module Cooling Structure With Moving Droplets for Mini LED Heat
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Solution Overview
Problem
Mini LED displays face challenges with passive heat dissipation methods that cannot quickly and effectively cool down high-density heat generated by local LED chip positions, leading to potential color shifts and reduced display performance.
Innovation Solution
An optical module with a heat dissipation structure featuring anodized aluminum substrates and cooling droplets that move between layers to absorb and dissipate heat efficiently, utilizing micro-nano channels for rapid heat transfer and controlled coolant flow to maintain effective cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If passive heat dissipation methods (cooling fan, heat dissipation hole, fixed heat dissipation structure) are used, then the device structure is simple and easy to manufacture, but the heat dissipation speed is insufficient and cannot quickly cool down high-density heat generated by mini LEDs
Solution Approach 1:
The patent applies the dynamics principle by using movable cooling droplets instead of fixed heat dissipation structures. The cooling droplets can dynamically move to different positions on the light plate depending on the heat generation needs, transforming a static heat dissipation system into a dynamic one that adapts to real-time thermal requirements.
Solution Approach 2:
The patent employs hydraulics by using liquid cooling droplets as the heat dissipation medium. The droplets move across the light plate surface to absorb and transfer heat, utilizing fluid properties to achieve efficient heat dissipation that overcomes the limitations of solid-state passive heat dissipation methods.
2Temperature
If fixed heat dissipation structures are used, then the manufacturing process is simple, but the system cannot quickly and locally cool down mini LEDs with uneven heat generation
Solution Approach 1:
The cooling system transitions from static to dynamic by enabling cooling droplets to move freely on the light plate surface. This allows the system to adapt to uneven heat generation patterns by concentrating cooling capacity at locations where mini LEDs generate the most heat, providing localized and adaptive thermal management.
Solution Approach 2:
The system exhibits self-service characteristics as the cooling droplets automatically respond to heat generation patterns without external control. The droplets naturally migrate toward high-temperature regions and perform heat dissipation where needed most, enabling the system to self-regulate based on real-time thermal conditions.
3Illumination intensity
If more mini LED lamp beads and chips are arranged in high-brightness partitions, then the display brightness and resolution are improved, but the heat generation increases causing local heating and color shift
Solution Approach 1:
The patent uses liquid cooling droplets to directly address the thermal management challenge posed by high-brightness mini LEDs. The liquid medium efficiently absorbs heat from the high-density LED arrangements, preventing local heating and the associated color shift problems while maintaining high display brightness.
Solution Approach 2:
The system changes the thermal parameters of the display by introducing active cooling that dynamically adjusts heat removal based on local temperature conditions. This allows the mini LEDs to operate at high brightness levels without accumulating excessive heat, maintaining both illumination intensity and color accuracy.
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 enables rapid cooling of mini LEDs, reducing temperature differences between adjacent elements and preventing display issues, with improved heat dissipation rates and extended service life of mini LED components.
Implementation Method 1
The surface properties of the first anodized aluminum layer and the second anodized aluminum layer form super-amphiphilic micro-nano channels used for the movement of the cooling droplets
Implementation Method 2
The cooling droplet may quickly wet, cover and absorb the heat of the light-emitting element
Implementation Method 3
The cooling droplet may quickly wet, cover and absorb the heat of the light-emitting element
Data Source
AI summary
An optical module includes a light plate and a heat dissipation structure. The heat dissipation structure includes a first substrate connected to the light plate, and a second substrate disposed under the first substrate. The first and second substrates are made of aluminum or an aluminum alloy material. A first anodized aluminum layer is disposed on a side of the first substrate adjacent to the second substrate. A second anodized aluminum layer is disposed on a side of the second substrate adjacent to the first substrate. A gap is defined between the first and second anodized aluminum layers, and there are disposed cooling droplets in the gap. When each light-emitting element is at a first heating value, the respective cooling droplet moves to a position under the light-emitting element. When each light-emitting element is at a second heating value, the respective coolant drop leaves from under the light-emitting element.