Selective Laser Melting Heat Sinks under Jet Impingement Cooling for Heat Dissipation of Higher Light Output LED Lighting in a Limited Space

In this study, we aimed to create heat sinks with higher heat dissipation capabilities for a compact light-emitting diode (LED) recessed downlight (CLRDL) under jet impingement cooling. We desired to use the sinks in limited space to maintain lower junction temperature and allow higher LED power. Perforated-finned heat sinks (PTFHSs) and metal-foam-like heat sinks (MFLHSs) fabricated using selective laser melting (SLM) were compared with a traditional finned heat sink (TTFHS). Two cooling fans with higher and lower velocity at Reynolds numbers of 16916 and 6594 were individually installed on each heat sink. Numerical simulations were performed using COMSOL rotating machinery and nonisothermal flow interface with the standard k-ε turbulence flow model. Validations were performed on this apparatus. The SLM heat sinks exhibited higher Nusselt numbers and lower thermal resistance than traditional heat sinks because of a relatively higher heat transfer coefficient and larger heat transfer area. For the proposed SLM heat sinks with larger surface areas, complex flow channels, and ventilation holes under jet impingement cooling, the PTFHS exhibited the highest heat transfer enhancement followed by MFLHS and TTFHS. The results contribute to solving the problems of heat dissipation of higher light output LED lighting.