Advanced Thermal Solutions, Inc. (ATS) was approached by a company interested in a new design for an outdoor LED unit that would be installed in gas station canopies. The original unit was bolted together and contained a molded plastic shroud that held the LED array, the PCB, and an extruded aluminum heat sink.
ATS engineers designed an aesthetically pleasing alternative that utilized natural convection cooling, while increasing the number of the LEDs in the array and its power. The engineers met the customer’s budget and thermal performance requirements.
• Challenge: Create an outdoor canopy device that would increase the number of LED in the array, increase power to maximum of 120 watts, and increase lumens, while cooling the device through natural convection.
• Chip/Component: The device had to hold an LED array and the PCB that powered it.
• Analysis: Analytical modeling and CFD simulations determined the optimal fin efficiency to allow air through the device and across the heat sink, the spreading resistance. The weight of the device was also considered, as it would be outside above customers.
• Solution: An aesthetically-pleasing, one-piece, casted unit with built-in electronics box for LED array and PCB was created. There was one inch of headroom between the heat sink and the canopy to allow for heat dissipation and the casting would allow heat transfer as well as allow air to flow through the system.
• Net Result: The customer was able to add LEDs to the array and increase power. The new unit also simplified the manufacturing process and cut manufacturing costs.