Thermal management of high-power LEDs

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Typical LED package including thermal management design LED package.jpg
Typical LED package including thermal management design
Thermal animation of a high powered A19 sized LED light bulb, created using high resolution computational fluid dynamics (CFD) analysis software, showing temperature contoured LED heat sink and flow trajectories CFD A19 LED Light Bulb.gif
Thermal animation of a high powered A19 sized LED light bulb, created using high resolution computational fluid dynamics (CFD) analysis software, showing temperature contoured LED heat sink and flow trajectories
Thermal animation of a high power density industrial PAR 64 LED downlight heat sink design, created using high resolution CFD analysis software, showing temperature contoured heat sink surface and interior and exterior flow trajectories CFD LED Free Convection Heat Sink Design.gif
Thermal animation of a high power density industrial PAR 64 LED downlight heat sink design, created using high resolution CFD analysis software, showing temperature contoured heat sink surface and interior and exterior flow trajectories
Typical thermal model of LED package. LED power dissipation is modeled as a current source; thermal resistance is modeled as a resistor; and the ambient temperature is modeled as a voltage source. Thermal model of LED package.jpg
Typical thermal model of LED package. LED power dissipation is modeled as a current source; thermal resistance is modeled as a resistor; and the ambient temperature is modeled as a voltage source.

High power light-emitting diodes (LEDs) can use 350 milliwatts or more in a single LED. Most of the electricity in an LED becomes heat rather than light (about 70% heat and 30% light). [1] If this heat is not removed, the LEDs run at high temperatures, which not only lowers their efficiency, but also makes the LED less reliable. Thus, thermal management of high power LEDs is a crucial area of research and development. It is necessary to limit both the junction and the phosphor particles temperatures to a value that will guarantee the desired LED lifetime. [2] [3]

Contents

Thermal management is a universal problem having to do with power density, which occurs both at higher powers or in smaller devices. Many lighting applications wish to combine a high light flux with an extremely small light emitting substrate, causing concerns with LED power management to be particularly acute.

An 80 W Chip-On-Board COB LED Module from an industrial light luminaire, thermally bonded to the heat-sink Chip-On-Board COB LED Module.JPG
An 80 W Chip-On-Board COB LED Module from an industrial light luminaire, thermally bonded to the heat-sink

Heat transfer procedure

In order to maintain a low junction temperature to keep good performance of an LED, every method of removing heat from LEDs should be considered. Conduction, convection, and radiation are the three means of heat transfer. Typically, LEDs are encapsulated in a transparent polyurethane-based resin, which is a poor thermal conductor. Nearly all heat produced is conducted through the back side of the chip. [4] Heat is generated from the p–n junction by electrical energy that was not converted to useful light, and conducted to outside ambience through a long path, from junction to solder point, solder point to board, and board to the heat sink and then to the atmosphere. A typical LED side view and its thermal model are shown in the figures.

The junction temperature will be lower if the thermal impedance is smaller and likewise, with a lower ambient temperature. To maximize the useful ambient temperature range for a given power dissipation, the total thermal resistance from junction to ambient must be minimized.

The values for the thermal resistance vary widely depending on the material or component supplier. For example, RJC will range from 2.6 °C/W to 18 °C/W, depending on the LED manufacturer. The thermal interface material’s (TIM) thermal resistance will also vary depending on the type of material selected. Common TIMs are epoxy, thermal grease, pressure-sensitive adhesive and solder. Power LEDs are often mounted on metal-core printed circuit boards (MCPCB), which will be attached to a heat sink. Heat conducted through the MCPCB and heat sink is dissipated by convection and radiation. In the package design, the surface flatness and quality of each component, applied mounting pressure, contact area, the type of interface material and its thickness are all important parameters to thermal resistance design.

Passive thermal designs

Some considerations for passive thermal designs to ensure good thermal management for high power LED operation include:

Adhesive

Adhesive is a thermal conductive interface layer, [5] which is commonly used to bond LED and board, and board and heat sinks and further optimizes the thermal performance. Current commercial adhesive is limited by relatively low thermal conductivity ~1 W/(mK).

Heat sink

Heat sinks provide a path for heat from the LED source to outside medium. Heat sinks can dissipate power in three ways: conduction (heat transfer from one solid to another), convection (heat transfer from a solid to a moving fluid, which for most LED applications will be air), or radiation (heat transfer from two bodies of different surface temperatures through Thermal radiation).

Although a bigger surface area leads to better cooling performance, there must be sufficient space between the fins to generate a considerable temperature difference between the fin and the surrounding air. When the fins stand too close together, the air in between can become almost the same temperature as the fins, so that thermal transmission will not occur. Therefore, more fins do not necessarily lead to better cooling performance.

For heat transfer between LED sources over 15 Watt and LED coolers, it is recommended to use a high thermal conductive interface material (TIM) which will create a thermal resistance over the interface lower than 0.2 K/W. Currently, the most common solution is to use a phase-change material, which is applied in the form of a solid pad at room temperature, but then changes to a thick, gelatinous fluid once it rises above 45 °C.

Heat pipes and vapor chambers

Heat pipes and vapor chambers are passive, and have effective thermal conductivities ranging from 10,000 to 100,000 W/m K. They can provide the following benefits in LED thermal management: [6]

PCB (printed circuit board)

Thick-film materials system

Package type

LED filament

The LED filament style of lamp combines many relatively low-power LEDs on a transparent glass substrate, coated with phosphor, and then encapsulated in silicone. The lamp bulb is filled with inert gas, which convects heat away from the extended array of LEDs to the envelope of the bulb. This design avoids the requirement for a large heat sink.

Active thermal designs

Some works about using active thermal designs to realize good thermal management for high power LED operation include:

Thermoelectric (TE) device

Thermoelectric devices are a promising candidate for thermal management of high power LED owing to the small size and fast response. [9] A TE device made by two ceramic plates can be integrated into a high power LED and adjust the temperature of LED by heat-conducting and electrical current insulation. [10] Since ceramic TE devices tend to have a coefficient of thermal expansion mismatch with the silicon substrate of LED, silicon-based TE devices have been invented to substitute traditional ceramic TE devices. Silicon owning higher thermal conductivity (149 W/(m·K)) compared with aluminum oxide(30 W/(m·K)) also makes the cooling performance of silicon-based TE devices better than traditional ceramic TE devices.

The cooling effect of thermoelectric materials depends on the Peltier effect. [11] When an external current is applied to a circuit composed of n-type and p-type thermoelectric units, the current will drive carriers in the thermoelectric units to move from one side to the other. When carriers move, heat also flows along with the carriers from one side to the other. Since the direction of heat transfer relies on the applied current, thermoelectric materials can function as a cooler with currents that drive carriers from the heated side to the other side.

A typical silicon-based TE device has a sandwich structure. Thermoelectric materials are sandwiched between two substrates made by high thermal conductivity materials. [12] N-type and p-type thermoelectric units are connected sequentially in series as the middle layer. When a high power LED generates heat, the heat will first transfer through the top substrate to the thermoelectric units. With an applied external current, the heat will then be forced to flow to the bottom substrate through the thermoelectric units so that the temperature of the high power LED can be stable.

Liquid cooling system

Cooling systems using liquids such as liquid metals, water, and stream [13] also actively manage high power LED's temperature. Liquid cooling systems are made up of a driving pump, a cold plate, and a fan-cooled radiator. [14] The heat generated by a high power LED will first transfer to liquids through a cold plate. Then liquids driven by a pump will circulate in the system to absorb the heat. Lastly, a fan-cooled radiator will cool the heated fluids for the next circulation. The circulation of liquids manages the temperature of the high power LED.

See also

Related Research Articles

A semiconductor is a material that has an electrical conductivity value falling between that of a conductor, such as copper, and an insulator, such as glass. Its resistivity generally falls as its temperature rises; metals behave in the opposite way. Its conducting properties may be altered in useful ways by introducing impurities ("doping") into the crystal structure. When two differently doped regions exist in the same crystal, a semiconductor junction is created. The behavior of charge carriers, which include electrons, ions, and electron holes, at these junctions is the basis of diodes, transistors, and most modern electronics. Some examples of semiconductors are silicon, germanium, gallium arsenide, and elements near the so-called "metalloid staircase" on the periodic table. After silicon, gallium arsenide is the second-most common semiconductor and is used in laser diodes, solar cells, microwave-frequency integrated circuits, and others. Silicon is a critical element for fabricating most electronic circuits.

Conduction is the process by which heat is transferred from the hotter end to the colder end of an object. The ability of the object to conduct heat is known as its thermal conductivity, and is denoted k.

In materials science, a metal matrix composite (MMC) is a composite material with fibers or particles dispersed in a metallic matrix, such as copper, aluminum, or steel. The secondary phase is typically a ceramic or another metal. They are typically classified according to the type of reinforcement: short discontinuous fibers (whiskers), continuous fibers, or particulates. There is some overlap between MMCs and cermets, with the latter typically consisting of less than 20% metal by volume. When at least three materials are present, it is called a hybrid composite. MMCs can have much higher strength-to-weight ratios, stiffness, and ductility than traditional materials, so they are often used in demanding applications. MMCs typically have lower thermal and electrical conductivity and poor resistance to radiation, limiting their use in the very harshest environments.

<span class="mw-page-title-main">Thermoelectric cooling</span> Electrically powered heat-transfer

Thermoelectric cooling uses the Peltier effect to create a heat flux at the junction of two different types of materials. A Peltier cooler, heater, or thermoelectric heat pump is a solid-state active heat pump which transfers heat from one side of the device to the other, with consumption of electrical energy, depending on the direction of the current. Such an instrument is also called a Peltier device, Peltier heat pump, solid state refrigerator, or thermoelectric cooler (TEC) and occasionally a thermoelectric battery. It can be used either for heating or for cooling, although in practice the main application is cooling. It can also be used as a temperature controller that either heats or cools.

<span class="mw-page-title-main">Heat sink</span> Passive heat exchanger that transfers the heat

A heat sink is a passive heat exchanger that transfers the heat generated by an electronic or a mechanical device to a fluid medium, often air or a liquid coolant, where it is dissipated away from the device, thereby allowing regulation of the device's temperature. In computers, heat sinks are used to cool CPUs, GPUs, and some chipsets and RAM modules. Heat sinks are used with high-power semiconductor devices such as power transistors and optoelectronics such as lasers and light-emitting diodes (LEDs), where the heat dissipation ability of the component itself is insufficient to moderate its temperature.

<span class="mw-page-title-main">Thermal paste</span> Fluid used to maximize thermal contact

Thermal paste is a thermally conductive chemical compound, which is commonly used as an interface between heat sinks and heat sources such as high-power semiconductor devices. The main role of thermal paste is to eliminate air gaps or spaces from the interface area in order to maximize heat transfer and dissipation. Thermal paste is an example of a thermal interface material.

<span class="mw-page-title-main">Thermoelectric materials</span> Materials whose temperature variance leads to voltage change

Thermoelectric materials show the thermoelectric effect in a strong or convenient form.

<span class="mw-page-title-main">Heat pipe</span> Heat-transfer device that employs phase transition

A heat pipe is a heat-transfer device that employs phase transition to transfer heat between two solid interfaces.

<span class="mw-page-title-main">Photodetector</span> Sensors of light or other electromagnetic energy

Photodetectors, also called photosensors, are sensors of light or other electromagnetic radiation. There are a wide variety of photodetectors which may be classified by mechanism of detection, such as photoelectric or photochemical effects, or by various performance metrics, such as spectral response. Semiconductor-based photodetectors typically use a p–n junction that converts photons into charge. The absorbed photons make electron–hole pairs in the depletion region. Photodiodes and photo transistors are a few examples of photo detectors. Solar cells convert some of the light energy absorbed into electrical energy.

<span class="mw-page-title-main">Thermal management (electronics)</span> Regulation of the temperature of electronic circuitry to prevent inefficiency or failure

All electronic devices and circuitry generate excess heat and thus require thermal management to improve reliability and prevent premature failure. The amount of heat output is equal to the power input, if there are no other energy interactions. There are several techniques for cooling including various styles of heat sinks, thermoelectric coolers, forced air systems and fans, heat pipes, and others. In cases of extreme low environmental temperatures, it may actually be necessary to heat the electronic components to achieve satisfactory operation.

The role of the substrate in power electronics is to provide the interconnections to form an electric circuit, and to cool the components. Compared to materials and techniques used in lower power microelectronics, these substrates must carry higher currents and provide a higher voltage isolation. They also must operate over a wide temperature range.

<span class="mw-page-title-main">Thermoelectric generator</span> Device that converts heat flux into electrical energy

A thermoelectric generator (TEG), also called a Seebeck generator, is a solid state device that converts heat directly into electrical energy through a phenomenon called the Seebeck effect. Thermoelectric generators function like heat engines, but are less bulky and have no moving parts. However, TEGs are typically more expensive and less efficient.

<span class="mw-page-title-main">Heat spreader</span> Device that tends to equalize temperature over its surface

A heat spreader transfers energy as heat from a hotter source to a colder heat sink or heat exchanger. There are two thermodynamic types, passive and active. The most common sort of passive heat spreader is a plate or block of material having high thermal conductivity, such as copper, aluminum, or diamond. An active heat spreader speeds up heat transfer with expenditure of energy as work supplied by an external source.

<span class="mw-page-title-main">Thermal copper pillar bump</span>

The thermal copper pillar bump, also known as the "thermal bump", is a thermoelectric device made from thin-film thermoelectric material embedded in flip chip interconnects for use in electronics and optoelectronic packaging, including: flip chip packaging of CPU and GPU integrated circuits (chips), laser diodes, and semiconductor optical amplifiers (SOA). Unlike conventional solder bumps that provide an electrical path and a mechanical connection to the package, thermal bumps act as solid-state heat pumps and add thermal management functionality locally on the surface of a chip or to another electrical component. The diameter of a thermal bump is 238 μm and 60 μm high.

AlSiC, pronounced "alsick", is a metal matrix composite consisting of aluminium matrix with silicon carbide particles. It has high thermal conductivity, and its thermal expansion can be adjusted to match other materials, e.g. silicon and gallium arsenide chips and various ceramics. It is chiefly used in microelectronics as substrate for power semiconductor devices and high density multi-chip modules, where it aids with removal of waste heat.

In heat transfer, thermal engineering, and thermodynamics, thermal conductance and thermal resistance are fundamental concepts that describe the ability of materials or systems to conduct heat and the opposition they offer to the heat current. The ability to manipulate these properties allows engineers to control temperature gradient, prevent thermal shock, and maximize the efficiency of thermal systems. Furthermore, these principles find applications in a multitude of fields, including materials science, mechanical engineering, electronics, and energy management. Knowledge of these principles is crucial in various scientific, engineering, and everyday applications, from designing efficient temperature control, thermal insulation, and thermal management in industrial processes to optimizing the performance of electronic devices.

<span class="mw-page-title-main">Failure of electronic components</span> Ways electronic components fail and prevention measures

Electronic components have a wide range of failure modes. These can be classified in various ways, such as by time or cause. Failures can be caused by excess temperature, excess current or voltage, ionizing radiation, mechanical shock, stress or impact, and many other causes. In semiconductor devices, problems in the device package may cause failures due to contamination, mechanical stress of the device, or open or short circuits.

Heat exchangers are devices that transfer heat to achieve desired heating or cooling. An important design aspect of heat exchanger technology is the selection of appropriate materials to conduct and transfer heat fast and efficiently.

<span class="mw-page-title-main">Thermopile laser sensor</span>

Thermopile laser sensors are used for measuring laser power from a few µW to several W. The incoming radiation of the laser is converted into heat energy at the surface. This heat input produces a temperature gradient across the sensor. Making use of the thermoelectric effect a voltage is generated by this temperature gradient. Since the voltage is directly proportional to the incoming radiation, it can be directly related to the irradiation power.

Thermal inductance refers to the phenomenon wherein a thermal change of an object surrounded by a fluid will induce a change in convection currents within that fluid, thus inducing a change in the kinetic energy of the fluid. It is considered the thermal analogue to electrical inductance in system equivalence modeling; its unit is the thermal henry.

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