Development of Radiator with Thermoplastic Polymer and Insert-Molded Aluminum Alloy Parts for Light-Emitting Diode Headlights

Abstract

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.

Research advances in preparation, mechanism and application of thermally conductive and electrically insulating polymer composites in thermal management materials: A review

“…Thermal conductive polymer composite is the key material to solve the heat dissipation of chip. 102 It can timely export the heat generated by luminescence, effectively reduce the temperature rise, and achieve the purpose of improving the luminescence efficiency and prolonging the service life. With the rapid development of science and technology, research and development of high λ polymer matrix composites with excellent comprehensive performance, optimize module structure, improve thermal management ability and reduce system price, especially the development of high λ polymer is one of the hot research directions in the future field.…”