A customer engaged in the stage lighting equipment manufacturing industry, the equipments were mainly high-power LEDs with the features of high luminance and huge heat emission volume, traditional air-cooled heat dissipation performed commonly, especially in summer and outdoors, equipments were easy to have breakdown or even damage. The customer contacted the R&D Department of Dongyuan Syscooling, and hoped to change the traditional air-cooled heat dissipation method into highly-efficient water-cooling heat dissipation method without changing the basic shape of equipments.
The overall dimension of the LED adopted in customer equipments was 54*54*6mm, and the power included three specifications, namely 120W, 160W and 200W respectively, in this design, we adopted the highest power of 200W as the heat source.
The customer didn’t want to change the basic shape of equipment, so the shell part of equipment couldn’t be adjusted, and the actually measured space of installable water cooling heads was 71*69*18mm.
We simulated that the customer's equipments are put into the 35℃ constant-temperature experimental box in summer, outdoors and without natural wind, the surface temperature of LED measured was 92℃, which was far higher than the safe temperature of LED product at 65℃; the objective of this water-cooling and heat dissipation design was to reduce the temperature within safe level.
*Because the workable space within customer equipment was small, the solution was adopted that only water cooling heads were installed within the equipment, and integrated water cooling box was connected on the outside;
*Design direction 1 of water cooling heads: based on the design experiences of the R&D Department, the heat dissipation area in the direction of length and width was sufficient, the design of internal water flow was in square column form, which could save certain cost and construction term for the customer;
*Design direction 2 of water cooling heads: the space was insufficient in the direction of height, so the method of water gap being vertical to the internal water route was not appropriate, the design was the method of water opening being parallel to the water route, and a bar-type partition was added between the water inlet and outlet;
*As discussed, simulated and calculated by the R&D Department, it was determined that the boundary dimension of the water cooling head was 65*56*14mm, which used pure copper material, and the internal water route adopted the square column form, and the water opening adopted G1/4 screw thread;
*The customer's unit equipment volume was relatively small, so the integrated water cooling box with relatively small volume was selected, which was also equipped with a slightly longer flexible hose to facilitate the customer to collectively place and manage the externally placed water cooling box;
*The thermal physics treatment was made on the final solution, at the constant temperature of CFD, the maximum temperature on the surface of LED was 53℃, which was lower than the safety temperature, so the designed passed the test.
The customer actually applied the solution to its LED equipments, without changing the basic shape of equipment, the temperature declined to 56℃ and was controlled within the safe temperature of LED, the equipment's stability and reliability was enhanced, and the market share was to certain extent enhanced.