Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights
Source abstract
Abstract
The increasing popularity of electric vehicles has increased the demand for lightweight auto parts. However, the excessive weight of traditional metal heat sinks has remained a concern. Metal has excellent thermal conductivity but low radiation efficiency. Conversely, thermoplastic polymers have excellent heat radiation efficiency but poor thermal conductivity. In this study, we propose a radiator constructed using thermoplastic polymer and insert-molded aluminum alloy parts to maintain the low junction temperature of light-emitting diodes (LEDs); the radiator’s weight is reduced through a combination of aluminum alloy and a thermally conductive polymer designed for automotive headlights. At an LED thermal load of 11.48 W, the measured temperature on the LED pad is 60.8 °C. The weight of the proposed radiator is 23.37% lighter than that of a pure metal radiator. When the lightweight radiator is used in high-power LED headlights, it effectively dissipates heat within a limited space.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Synthesis and properties of polymers · Engineering Applied Research · GaN-based semiconductor devices and materials
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Graduate Institute of Precision Engineering, National Chung Hsing University, No. 145, Xingda Rd., South Dist., Taichung 402, Taiwan
R&D Center, Dayei Precise Technology Co., Ltd., No. 20, Ln. 372, Kinmen St., Banqiao Dist., New Taipei City 22071, Taiwan
R&D Center, PUZI Enterprise Co., Ltd., No. 20, Ln. 372, Kinmen St., Banqiao Dist., New Taipei City 22071, Taiwan
R&D Center, Nytex Composites Co., Ltd., 17F., No. 94, Sec. 1, Sintai 5th Rd., Sijhih Dist., New Taipei City 221, Taiwan
Department of Mechanical Engineering, Advanced Institute of Manufacturing with High Tech Innovations, National Chung Cheng University, 168, University Rd., Min Hsiung, Chiayi 62102, Taiwan
Funding
DAYEI PRECISE TECHNOLOGY CO., LTD, PUZI Enterprise CO. LT., and the Ministry of Science and Technology, The Republic of China
References (40)
Show source-provided references
1. Energy savings in greenhouses by transition from high-pressure sodium to LED lighting10.1016/j.apenergy.2020.116019 ↗
2. Calculations of energy savings using lighting control systems
3. Zhang, H., Liu, D.F., Wei, Y.W., and Wang, H. (2021). Asymmetric Double Freeform Surface Lens for Integrated LED Automobile Headlamp. Micromachines, 12.10.3390/mi12060663 ↗
4. All-reflective RGB LED flashlight design for effective color mixing10.1364/OE.24.004411 ↗
5. Experimental investigation on the thermal performance of threedimensional vapor chamber for LED automotive headlamps10.1016/j.applthermaleng.2019.03.049 ↗
6. Light extraction efficiency enhancement of flip-chip blue light-emitting diodes by anodic aluminum oxide10.3762/bjnano.9.152 ↗
7. Accelerated degradation test investigation for life-time performance analysis of LED luminaires10.1109/TCPMT.2019.2958852 ↗
8. Ye, Z.T., Chen, C.L., Chen, L., Tien, C.H., Nguyen, H.T., and Wang, H. (2019). Hollow light guide module involving mini light-emitting diodes for asymmetric luminous planar illuminators. Energies, 12.10.3390/en12142755 ↗
9. Optimization of InGaN-based LED package structure for automotive adaptive driving beam headlamp10.1149/2162-8777/ab9dc6 ↗
10. CSP-LEDs Combined with Light Guide without Reflective Matrix for Antiglare Design10.1109/ACCESS.2020.3019314 ↗
11. Ye, Z., Chang, C., Juan, M., and Chen, K. (2020). Luminous Intensity Field Optimization for Antiglare LED Desk Lamp without Second Optical Element. Appl. Sci., 10.10.3390/app10072607 ↗
12. System-level lifetime prediction for LED lighting applications considering thermal coupling between LED sources and drivers10.1109/JESTPE.2018.2850845 ↗
13. Lifetime prediction of a multi-chip high-power LED light source based on artificial neural networks10.1016/j.rinp.2018.11.001 ↗
14. A lifetime prediction method for LEDs considering real mission10.1109/TPEL.2016.2641010 ↗
15. Simplified and accelerated method of LED lamp useful life estimation10.1007/s12647-019-00302-2 ↗
16. The influence of junction temperature variation of LED on the lifetime estimation during accelerated aging test10.1109/ACCESS.2018.2885578 ↗
17. Adhikari, R., Beyragh, D., Pahlevani, M., and Wood, D. (2020). A numerical and experimental study of a novel heat sink design for natural convection cooling of LED grow lights. Energies, 13.10.3390/en13164046 ↗
18. Kilic, M., Aktas, M., and Sevilgen, G. (2020). Thermal assessment of laminar flow liquid cooling blocks for LED circuit boards used in automotive headlight assemblies. Energies, 13.10.3390/en13051202 ↗
19. Analysis of mini-LED light-off phenomenon based on FEM simulation10.3788/YJYXS20203501.0053 ↗
20. Numerical analysis on the thermal performances of different types of fin heat sink for high-power LED lamp cooling
21. Optimization of thermal design of ribbed flat-plate fin heat sink10.1016/j.applthermaleng.2016.03.119 ↗
22. Optimization of the thermal distribution of multi-chip LED package10.1016/j.applthermaleng.2017.07.136 ↗
23. Assessment of LED lamps components and materials for a recycling perspective10.1016/j.wasman.2020.04.028 ↗
24. Assessment of end-of-life design in solid-state lighting10.1088/1748-9326/aa7ab1 ↗
25. Experimental investigation on active heat sink with heat pipe assistance for high-power automotive LED headlights10.1016/j.csite.2021.101503 ↗
26. Dual-separated cooling channel performance evaluation for high-power led Pcb in automotive headlight10.1016/j.csite.2021.100985 ↗
27. Case study of liquid cooling of automotive headlights with hollow fiber heat exchanger10.1016/j.csite.2021.101689 ↗
28. Huang, Y., Luo, W., Wang, H., Feng, S., Kuo, C., and Lu, C. (2017). How smart LEDs lighting benefit color temperature and luminosity transformation. Energies, 10.10.3390/en10040518 ↗
29. Lee, C., Lim, M., Kim, C., and Bae, S.J. (2021). Reliability Analysis of Accelerated Destructive Degradation Testing Data for Bi-Functional DC Motor Systems. Appl. Sci., 11.10.3390/app11062537 ↗
30. Design of fins with a grooved heat pipe for dissipation of heat from high-powered automotive LED headlight10.1016/j.enconman.2018.11.021 ↗
31. Investigation of Characteristics and thermal loading of LED bulbs for automatics headlights10.20858/tp.2018.13.3.8 ↗
32. Ying, S.P., Chen, B.M., Fu, H.K., and Yeh, C.Y. (2021). Single Headlamp with Low- and High-Beam Light. Photonics, 8.10.3390/photonics8020032 ↗
33. Freeform surface design for high-efficient LED low-beam headlamp lens10.1016/j.optcom.2020.126269 ↗
34. Design of a high-efficiency LED low-beam headlamp using Oliker’s compound ellipsoidal reflector10.1364/AO.385680 ↗
35. Achromatic LED-based projection lens design for automobile headlamp10.1016/j.ijleo.2019.05.086 ↗
36. Improving motorcycle motion perception by using innovative motorcycle headlight configurations: Evidence from simulator and test-track experiments10.1016/j.aap.2021.106118 ↗
37. You, Z., Yang, D., Zhou, P., Hai, Y., Liu, D., and Hou, F. (2010, January 16–19). Heat transfer analysis of vapor chamber heat pipe for high power LED package. Proceedings of the 2010 11th International Conference on Electronic Packaging Technology & High Density Packaging, Xi’an, China.
38. Thermal simulation and optimization design on a high-power LED spot lamp10.1007/s11801-011-0142-8 ↗
39. Thermal effects on LED lamp with different thermal interface materials10.1109/TED.2016.2615882 ↗
40. A parametric study on heat dissipation from a LED-lamp10.1016/j.applthermaleng.2016.08.032 ↗