Research Papers

Advanced Natural Convection Cooling Designs for Light-Emitting Diode Bulb Systems

[+] Author and Article Information
James Petroski

6611 W Snowville Rd.,
Brecksville, OH 44141
e-mail: James.Petroski@gmail.com

Contributed by the Electronic and Photonic Packaging Division of ASME for publication in the JOURNAL OF ELECTRONIC PACKAGING. Manuscript received September 17, 2013; final manuscript received August 15, 2014; published online September 19, 2014. Assoc. Editor: Y. C. Lee.

J. Electron. Packag 136(4), 041005 (Sep 19, 2014) (8 pages) Paper No: EP-13-1106; doi: 10.1115/1.4028331 History: Received September 17, 2013; Revised August 15, 2014

The movement to light-emitting diode (LED) lighting systems worldwide is accelerating quickly as energy savings and reduction in hazardous materials increase in importance. Government regulations and rapidly lowering prices help to further this trend. Today's strong drive is to replace light bulbs of common outputs (60 W, 75 W, and 100 W) without resorting to compact fluorescent (CFL) bulbs containing mercury while maintaining the standard industry bulb size and shape referred to as A19. For many bulb designs, this A19 size and shape restriction forces a small heat sink which is barely capable of dissipating heat for 60 W equivalent LED bulbs with natural convection for today's LED efficacies. 75 W and 100 W equivalent bulbs require larger sizes, some method of forced cooling, or some unusual liquid cooling system; generally none of these approaches are desirable for light bulbs from a consumer point of view. Thus, there is interest in developing natural convection cooled A19 light bulb designs for LEDs that cool far more effectively than today's current designs. Current A19 size heat sink designs typically have thermal resistances of 5–7 °C/W. This paper presents designs utilizing the effects of chimney cooling, well developed for other fields that reduce heat sink resistances by significant amounts while meeting all other requirements for bulb system design. Numerical studies and test data show performance of 3–4 °C/W for various orientations including methods for keeping the chimney partially active in horizontal orientations. Significant parameters are also studied with effects upon performance. The simulations are in good agreement with the experimental data. Such chimney-based designs are shown to enable 75 W and 100 W equivalent LED light bulb designs critical for faster penetration of LED systems into general lighting applications.

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Fig. 1

LED bulb construction

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Fig. 2

Prototype V3 assembly

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Fig. 3

V3 top view with annular chimney

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Fig. 4

Test setup (typical)

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Fig. 5

IR image of V3 in horizontal position

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Fig. 6

CFD image of V3 horizontal position (only heat sink part shown for clarity)

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Fig. 7

V3 design orientation sensitivity

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Fig. 8

Prototype V6 assembly

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Fig. 9

V6 heat sink detail

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Fig. 10

V6 assembly top view

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Fig. 11

IR image of V6 assembly

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Fig. 12

Air flow in chamber, horizontal orientation

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Fig. 13

Air flow into chimney core

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Fig. 14

Velocity vector and contour plot

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Fig. 15

Prototype V8 assembly

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Fig. 16

V8 assembly top view

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Fig. 17

V8 heat sink detail

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Fig. 18

IR image of V8 vertical up test

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Fig. 19

CFD simulation of V8 vertical up test

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Fig. 20

Performance of V8 in vertical up orientation



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