LED Lamp Thermal Solution Case Study

Introduction

A household named consumer product company sought Aavid, Thermal division of BoydCorporation, to analyze and design the thermal solution for two of their LED based lampproducts. This company requested Aavid’s support throughout the product developmentprocess until a functional thermal solution was realized and could be presented at theirSummit Meeting for board approval.

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The Challenge

-The table lamp consists of 20 LEDs each dissipating about 0.64W (12.8W total). Aavidmust determine where these LEDs will be mounted on a ring shaped flex pcb in twoarrays. The Lamp base will be die cast and will house the power supply (ballast) whichmay dissipate an additional 2-3W.

-The desk lamp consists of 4 high luminous LEDs each could dissipate up to 4.5W;however total dissipation from the 4 LEDs does not exceed 10W at any time. These LEDsmay be mounted to a PCB or metal depending on the thermal solution. Aavid’s job will beto figure out how to spread and transport the heat down into the spine and ultimately tothe base.

-Both thermal solutions must be functional, manufacturable, and not impact the existing

The Solution

Aavid followed its process to find the best thermal solution within the designconstraints:

• Baseline Thermal Modeling and Analysis: LED packages based on their data sheets,Flex PCB was based on its copper stack-up, All plastic layers, sheet metal layers and air-gap in between surface, All significant heat generating components, including the ballast,and Base simulations were carried out (as is) in a natural convection environment at thespecified ambient

• Thermal Design and Optimization Exploration: Adding heat spreaders beneath LEDs toavoid concentrated heat sources, Spreading the heat uniformly over the available metalcomponents , Maximize natural convection from exposed surfaces, Add vent holes orchannels for table light as necessary, Design heat pipe and/or sink solution wherenecessary.

• Prototype Solution Design: Assist in design and manufacture working prototype in timefor the customer’s board meeting for presentation.

The Deliverables/Results

Aavid presented baseline simulation results, flow and temperature contour plots andspecific guidelines/recommendations on airflow, ventilation, conduction to sheet metal,conduction layers and thicknesses, thermal interface materials, and vent holes, for bothTable and Desk lamp products.

-Aavid developed a CAD database suitable for prototype of the thermal solutions forboth products and then completed a manufactured prototype in time for the Summit.Also at this meeting the client was ensured a sound functional solution whilemaintaining the integrity of the design’s intent.

-After the board’s approval at the Summit, this company has successfully launched bothproducts into the marketplace with the support of Aavid.

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