Reversible Refrigerant Flow Heatsink for LED Temperature Uniformity
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Solution Overview
Problem
In photolithography processes, LED light source modules with multiple LED chips face premature replacement due to temperature variations, leading to inefficient cooling and reduced lifespan, as existing cooling methods either undercool or overcool the chips, resulting in uneven temperature distribution and early module replacement.
Innovation Solution
A light source device with a heatsink and refrigerant flow direction switching mechanism that allows reversible refrigerant flow through channels, optimizing heat exchange and extending LED chip lifespan by averaging temperature distribution across the LED chips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If multiple channels are formed to cool two-dimensionally arranged LED chips, then temperature uniformity is improved, but device complexity increases
Solution Approach 1:
The cooling system is divided into multiple independent channels, each responsible for cooling specific regions of LED chips. This segmentation allows targeted cooling control for different chip locations, achieving temperature uniformity across the two-dimensional LED array without requiring an overly complex integrated cooling structure.
Solution Approach 2:
The patent transitions from one-dimensional linear cooling to two-dimensional planar cooling by arranging channels in a grid pattern that corresponds to the two-dimensional LED chip layout. This dimensional expansion enables effective heat removal from all LED chips regardless of their position on the substrate.
2Productivity
If channel width is increased to improve refrigerant flow rate, then cooling power is improved, but temperature uniformity deteriorates
Solution Approach 1:
The cooling system uses multiple narrower channels instead of a single wide channel. Each channel maintains sufficient refrigerant flow velocity while the collective network of channels provides adequate total cooling capacity. This segmentation ensures uniform temperature distribution across LED chips without sacrificing overall cooling effectiveness.
Solution Approach 2:
Different channels are positioned to serve specific local regions of LED chips, with each channel optimized for its designated cooling zone. This local optimization ensures that refrigerant flow characteristics are appropriate for each region, maintaining temperature uniformity while achieving sufficient total cooling power.
3Illumination intensity
If LED chips are arranged two-dimensionally to increase light output, then illuminance is improved, but cooling complexity increases
Solution Approach 1:
The two-dimensional LED chip array is paired with a segmented cooling system where multiple channels are arranged in corresponding rows and columns. This segmentation allows the cooling system to match the two-dimensional light output configuration without requiring excessive complexity, as each channel group independently manages heat from its associated LED region.
Solution Approach 2:
The channel structure serves multiple functions simultaneously: it provides thermal management for two-dimensionally arranged LED chips, maintains structural support for the LED array, and enables efficient refrigerant distribution across the entire chip surface. This multi-functionality reduces overall system complexity despite the two-dimensional configuration.
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 delays the replacement timing of the LED light source module by extending the lifespan of LED chips through improved temperature uniformity and efficient cooling, allowing for more efficient use of LED chips and reducing waste.
Implementation Method 1
a heatsink configured to cool the plurality of LEDs... flowing refrigerant through the channels
Implementation Method 2
flowing refrigerant through the channels... cooling power of refrigerant
Data Source
AI summary
An LED light source module includes a circuit board, solid-state light emitting elements arranged on the circuit board, a heatsink disposed in contact with the circuit board and having a channel formed inside, through which refrigerant flows, and a switching unit configured to switch a flow direction of refrigerant through the channel to an opposite direction.