Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights
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 exc...
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| Format: | Article |
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MDPI AG
2022-05-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/12/11/5385 |
| _version_ | 1827665726567088128 |
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| author | Yenlung Chen Juikun Chang Chun Huang Changche Chiu Wei Lai Zhiting Ye Pin Han |
| author_facet | Yenlung Chen Juikun Chang Chun Huang Changche Chiu Wei Lai Zhiting Ye Pin Han |
| author_sort | Yenlung Chen |
| collection | DOAJ |
| description | 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. |
| first_indexed | 2024-03-10T01:32:09Z |
| format | Article |
| id | doaj.art-ef7bc4b2cb2e4d22a516c658eed9a89d |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-10T01:32:09Z |
| publishDate | 2022-05-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-ef7bc4b2cb2e4d22a516c658eed9a89d2023-11-23T13:40:49ZengMDPI AGApplied Sciences2076-34172022-05-011211538510.3390/app12115385Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode HeadlightsYenlung Chen0Juikun Chang1Chun Huang2Changche Chiu3Wei Lai4Zhiting Ye5Pin Han6Graduate Institute of Precision Engineering, National Chung Hsing University, No. 145, Xingda Rd., South Dist., Taichung 402, TaiwanR&D Center, Dayei Precise Technology Co., Ltd., No. 20, Ln. 372, Kinmen St., Banqiao Dist., New Taipei City 22071, TaiwanR&D Center, Nytex Composites Co., Ltd., 17F., No. 94, Sec. 1, Sintai 5th Rd., Sijhih Dist., New Taipei City 221, TaiwanDepartment of Mechanical Engineering, Advanced Institute of Manufacturing with High Tech Innovations, National Chung Cheng University, 168, University Rd., Min Hsiung, Chiayi 62102, TaiwanDepartment of Mechanical Engineering, Advanced Institute of Manufacturing with High Tech Innovations, National Chung Cheng University, 168, University Rd., Min Hsiung, Chiayi 62102, TaiwanDepartment of Mechanical Engineering, Advanced Institute of Manufacturing with High Tech Innovations, National Chung Cheng University, 168, University Rd., Min Hsiung, Chiayi 62102, TaiwanGraduate Institute of Precision Engineering, National Chung Hsing University, No. 145, Xingda Rd., South Dist., Taichung 402, TaiwanThe 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.https://www.mdpi.com/2076-3417/12/11/5385LED headlightthermal conductivitythermoplastic polymeraluminum alloycomposite radiator |
| spellingShingle | Yenlung Chen Juikun Chang Chun Huang Changche Chiu Wei Lai Zhiting Ye Pin Han Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights Applied Sciences LED headlight thermal conductivity thermoplastic polymer aluminum alloy composite radiator |
| title | Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights |
| title_full | Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights |
| title_fullStr | Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights |
| title_full_unstemmed | Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights |
| title_short | Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights |
| title_sort | development of radiator with thermoplastic polymer and insert molded aluminum alloy parts for light emitting diode headlights |
| topic | LED headlight thermal conductivity thermoplastic polymer aluminum alloy composite radiator |
| url | https://www.mdpi.com/2076-3417/12/11/5385 |
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