Thermal management has been one of the major obstacles when designing a high-power LED light. The common method such as aluminum extrusion and die casting are unable to achieve satisfaction for two main reasons:
(1) In a very large heat sink, the air does not always travel through the center. Therefore, the heat cannot dissipate effectively regardless of the shape.
(2) If the first problem is solved, as the wattage increases, the size of heat sink must increase proportionally. However, we should consider the weight capacity on standard high mast poles, which are designed to carry the weight of existing high-intensity discharge (HID) luminaries. For the kilo-watt LED application, using the common tooling method will result in producing an oversized heat sink that weights significantly more than the existing HID lamps. In addition to that, a bulky lamp simply cannot withstand high winds. Therefore, the idea of designing an oversized lamp is not only costly, but impractical.
In order to solve the problems above, combining small wattage modules for a high-power LED light is merely a temporary solution to achieve the adequate heat dissipation. Indeed, a kilo-watt LED light can be assembled from modules and seems to be a quick solution to the problem stated in paragraph (1) above: The challenge to effectively dissipate the center heat. However, as the number of assembly modules increases, the total weight and cross-section area must increase as well. More importantly, additional assembly modules will lead to more joints in the structure and affect the lamp’s overall durability.
To take advantage and utilize LED’s unique characteristics in harsh and extreme environments, our team has developed core competencies on optics, electronics and thermal engineering. To overcome the challenge stated above, we have developed new cooling concepts.
(1) Penetrable Side-wing Heat Transmission
(2) Penetrable Z-axis Heat Transmission
With the combination of new cooling designs, we have successfully created a high-power LED light with similar size, weight and light output as the kilo-watt HID lamp. Spinlux own multiple patents for the kilo-watt thermal system and have additional US and Germany patents pending.
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i. Ultra Lightweight：
By separating the LED compartment and heat sink, we have achieved the ideal thermal management and also significantly reduced the overall weight and dimension of the luminaire.
ii. Minimizing the Cross-section：
The development of Z-axis thermal structure minimizes the cross-section area of LED compartment, reducing its overall size and weight to the standard HID lamp. In other words, Spinlux’s Ultra-high Power LED Series is designed to “retrofit” with any fitting for HID lamps.
iii. High Durability and Reliability：
Spinlux’s Ultra-high Power LED Series are designed with one “single” unit of power supply. Our focus is on the overall durability by minimizing the number of assembly parts and maintaining a strong core structure.
iv. Shock and Wind Resistance：
Designed with a compact and durable structure, the Ultra-high Power LED Series is capable to withstand high-scale wind loads and extreme shock.
v. Unaffected by Dust Fallout：
Dust can often clog up in the heat sink overtime and reduce the air flow. With the penetrable design, the heat structure will remain dust free.
vi. Up-lighting and 360 Degree Adjustable Bracket：
For the general design of a LED light, the heat sink is mostly located on the back of the light fixture. In the down lighting application, the heat generated from the back will be dissipated upward naturally. The problem arises when the light beam is pointing upward, rising heat will be blocked by the heat sink itself. This may not be a concern in the low-power lamps, but a kilo-watt LED light with a gigantic heat sink will not be able to endure its heat being trapped down. Therefore, common high-power LED lights are not suitable for the up-lighting application. With our patented structures, the heat will dissipate effectively in any direction.