Current problems of the structure and cooling system for kilo-watt LED lights：
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.
Spinlux Core Technology
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.
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.
Existing problems with the LED lighting optical design：
To have the ability to design a high quality LED lighting product there needs to be a combination of the following factors in place. It is necessary to have
(i) a profound knowledge in a geometrical optics combined with good understanding of a three-dimensional space analytic geometry,
(ii) a good grasp of LED optics’ special chracteristics, and
(iii) the ability to effectively utilize optical simulation software tools and self-development programs.
Many engineers experienced in LED illumination optical design that enter the field of optoelectronics, lack the technical skills in CAD to establish the concept of a 3-D space. The same is true for mechanical engineers that enter the area of LED optoelectornics. As a result of their limited skillset, the performance of the resulting LED product’s optical design will not reach its maximum potential.
Spinlux Core Technology
SpinLux optical R & D team accumulated a wealth of experience in the lighting optical design (from traditional light halogen bulbs, HID to LED, OLED, LD), multi-mode optical design (Reflector, TIR optic, (Fresnel) Lens, Light guide system, FF (free form surface), MR (multi-reflector), Hybrids (projector) type, etc.), and a broad variety of lighting products (all types of LED lamps, LED lights / tunnel lights, LED steam / machine / bicycle light, LED flashlight, numerous types of indoor / outdoor lighting, etc.). Our R & D team possesses extensive knowledge in both 3-D mechanical design, as well as LED photoelectronics. We have profound expertise in geometrical optics and three-dimensional analytic geometry. Furthermore, our engineers are experienced in LED optical design, optical simulation and complex high level surfaces. We are able to develop designs by taking into account and combining knowledge from all important areas such as Light pattern, Optical efficiency, Shape of a light distribution curve, FWHM and 10% value in addition to the cd / lm value …… etc. Therefore, we have the capability to design exceptional high performance LED lighting products, that add value to our customers. On top of that, all our designs are in compliance with optical specifications of various countries and international lighting product requirements.
Spinlux LED illumination optics design experience
High performance (high optical efficiency and cd / lm value) Projector Lamp with different beam spread
High Mast Lighting, Infra-red Illuminator, Track Vehicle Headlight
All kinds of LED indoor / outdoor lighting design
All kinds of light pattern designs
Projector Lighting with white LED, NIR LED or LD
Optical element design : Reflector, TIR optic, (Fresnel)Lens, Light guide system
E-Mark LED Automotive Headlamp & Tail Lamp
E-Mark LED Motorcycle Headlamp & Tail Lamp
K-Mark LED Bicycle Headlamp & Tail Lamp
CIE or CJJ 45-2006 LED Street Lighting or Tunnel Lighting
Examples and Comparison
CURRENT PROBLEMS OF LED HIGH MAST：Thermal management has been one of the major obstacles when designing an ultra high-power LED light. There are 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 unproportionally.
SPINLUX CORE TECHNOLOGYTo overcome the challenge stated above, we have developed new cooling concepts.
(1) Penetrable Side-wing Heat Transmission Structure.
(2) Z-axis Heat Transmission Structure.
Instead of guiding the cool air flow into the center of heat sink, heat will be driven from center to two sides and the penetrable fin modules in two side wings will allow the air flow freely to come and go in all X, Y and Z axis. High efficiency of the convection makes the small size heat sink feasible.