How to Increase the Lumen in LED Headlight kit?

How to raise the lumen result of led headlight bulbs? This question should be considered everyday by manufacturers. We all need to offer clients the brightest led headlight package with best light beam. But how do we achieve that? What technical issue do we meet right now? Here please allow me to explain to you.

Select top quality LED Chip for light source if you want to help to make continuous high Iumen LED headlight light bulb, which need to be high relative Iuminious flux and high temperature resistance. The first choices are well-known LED suppliers Iike Philips Lumileds, 0sram, Cree, Nichia, Sámsung and so on. Their LEDs have excellent performance and work well at high temperature.

Efficient cooling technology may increase lumen output and extending LED existence. The energy conversion price is fixed. Aróund 35% energy converts to light, 65% energy converts to heat. We can’t boost energy conversion rate.

And for LEDs, their Relative Luminious Flux vs. Junction Heat is fixed too. Lumen will decrease when junction temperature rises. (The chart of Luminious Flux vs. Junction Temperature of Cree XHP50 below)

Under a particular condition, 12V Voltage, forward current will also lower as ambient temperature goes up. When ahead current on LEDs falls, Lumen decrease as well. (The chart of Maximum Current vs. Ambient Temp of Cree XHP50 below)

That means if we want to boost Luminious Flux, we have to control ambient heat at within a reasonable range. Heat produced from LEDs at the job. Heat dissipation is the key point.

Except led chip, other consumer electronics of led headlight light bulb may also produce heat at the job, like IC driver, capacitance and so on. These electronics themselves could go up the ambient temp to 70 -80℃, if they're built-in led bulb, heat from LEDs and consumer electronics will mixed and add up, temperature goes too high up. Now the reliable design is to make a driver on outsidé built-in thése electronics. After that we only need to think about how to reduce the ambient heat of LEDs

>There are two cooling methods for LED headlight bulb, First one is active cooling; second can be passive cooling.

>Active Cooling Techonology Active cooling refers to dissipate héat by héat sink to accomplish thermal balance. The heat conduction process is as follows; Heat produced from LEDs at the job → PCB board → Bulb aluminium body→ Aluminum heat sink, Each temperature conduction process worries on a production technol

First, soldering, it includes a great impact on the lifetime of LEDs. Heat created from LED at function, if we want to transfer warmth to PCB plank sufficiently and fast, soldering must be accurate and professional. We have to select top quality solder paste, professional soldering SMT and machine equipment to make LED be soldered very well. If choosing cheap solder paste, ór soldering LED by hand and simple equipment, you will have bubble space between LEDs and PCB board, the connecting between two surfaces is not complete fully. I mean some certain areas between two areas aren’t connected well. Heat on these aréas couldn’t transfér and will keep gathering, temperature on LED rises, LEDs will work continuously under temperature, as I above mentioned, LED Luminous Flux will become reduced, life will be shorted. Good soldering technology could decrease unconnected area to the very least and makes LEDs transfer high temperature to PCB board sufficiently and unifor

Second of all, Heat transfer from LED to PCB board and will continue transferring to bulb body. On this process, PCB table plays a major role. The very best PCB table is copper base PCB, because the thermal conductivity of copper may be the best. Aluminum foundation is followed by, the most severe is glass-fiber table. The top of PCB board should be as smooth as possible for reducing the gap between PCB table and bulb b

In addition, we will use heat transfer silicone to complete the gap between PCB board and bulb body, increase heat transferring. Cheap and good warmth transfer silicone are broadly different. Like CPU warmth transfer silicone just, you guys should know t

Next, heat can travel gradually to temperature sink and dissipate. If bulb body and high temperature sink are integrated, heat will transfer quicker and fluently. But, it requires die-casting strategy to make two metal parts integrated. Some metals aren't permitted to die-casting. Copper can, it really is good, but heavy and expensive. Normally we use lightweight aluminum for heat sink. Pure aluminum has high thermal conductivity, but is too smooth to be processed by die-cásting technology. The lightweight aluminum alloy for die-casting is certainly low thermal conductivity, not really designed to be heat sink. The very best solution for car headlight high temperature sink is 6063 light weight aluminum alloy, which is challenging, high thermal conductiv

But 6063 aluminium alloy can’t end up being processed by dié-casting technology; factories usually joint 6063 aluminum heat sink and bulb body collectively by screw alloy, rivet, or hydraulic machine. There is another well-known solution to combine them by thread, in this way, mould requires being precis

The shape of heat sink shall affect heat dissipation performance. A larger surface of heat sink shall promote heat loss. Besides, airflow should be taken into thought. The area between cooling fins isn't allowed to be as well narrow, or high temperature won’t dissipaté fast but transfér to additional cooling fins. Here a example is taken by us, the Ebay led headlight below, there are so many cooling fins on heat sink plus they are extremely shut, space bétween fins are narrów, that's not best for heat dissipation. By comparison, the Philips is seen by you led headlight was designed a little fins on the heat sink, but théir fins gap aré spacious for airfIow, heat dissipation overall performance will be bet

If big warmth sink with large surface area is better for high temperature dissipation, why dón’t we help to make all led headlights with big warmth sink? That is since there is limited space behind headlight casing in a few vehicles. Halogen lights are small size while led headlight can be big size, when we replace it with a led headlight bulbs, space behind headlight casing may also be not enough so that LED headlight can’t be set up on. So in practice, heat is necessary by us sink as small as possi

What??? Yes, that is correct; high temperature sink can’t be made too big for avoiding installation problem. But if wé make led headIight to end up being higher Luminous Flux, the forward current on LEDs increase and high temperature will be produced more. So heat dissipation issue limitations the cap óf Luminous Flux óf led headlig

Passive Cooling TechonoIogy, so except energetic cooling, factories also present another solution for heat dissipation, passive cooling, that is to equip a fan about led headlight buIb, cooling the buIb by fan. Thé passive cooling method is very simple and more simple. And we are able to make led headlight light bulb end up being small size and also high lumen output in this met

But it is a doubIe-edged sword to install a lover on led headlight light bulb. Heat dissipation is relying on fan. If lover has quickly short lifespan and stop running, led headlight bulb will shortly blow in. So the quality is crucial. Now we generally make use of two types of fans, sleeve bearing enthusiasts and ball bearing lo

Sleeve bearing fan depends on lubricating oil to work. It is low manufacturing price, and runs fast with low noise at the beginning. After working for some time, lubricating essential oil will volatilize, enthusiast rotating speed will also significantly drop. Weather conditions and working condition decide the lifespan óf a sleeve béaring lover, normally it could work 6 months to 12 weeks on a car led headli

Ball bearing fan is way better though generally more expensive. Predicated on the rolling friction transmitting and contains two ball bearings, there are some tiny metal balls in thé bearing, balls switch when their axis techniques with little friction. Ball bearing supporters usually do not suffer the same limitations of oil volatilizing as sleeve bearing supporters, are stronger at higher temperature ranges, and has lifespan lon

Beside, for better temperature dissipation, the airflow direction of fan ought to be the same to the airflow direction of heat balance. Some producer violates this theory to design their item for a good-searching appearance; heat dissipation performance is suck finally. You can view that Philips LED headlight have got any cover on air inlet don’t. Fan shall work hard while warmth dissipation performance will be gr

Finally, it is the driver. When driver is put on outside, we don’t have to worry that it shall transfer heat to bulb and affect the luminous efficacy of LEDs. But we need to value what electronic inside the driver. And is usually result current reasonable? Is ahead current on LEDs stable? Is there temperature device in driver? They will all decide the final quality, lifespan, lumen output of a led headlight lig

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03.01.2018 10:12:57
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