...
We will use this thermal adhesive to stick the heatsink (or heat pipe) to the lights boards: https://www.amazon.ca/MG-Chemicals-Thermally-Conductive-Adhesive-Fast/dp/B07D18R5Z5
We should potentially discuss this a little more since we probably want to be able to remove the lights boards without removing the heatsink.
Cree has amazing documentation on their lights and thermal performance and design in the pages linked on this page: https://www.cree.com/led-components/products/xlamp-leds-discrete/xlamp-xp-e2
...
Using the heat pipes and find from a PC CPU cooler might be a good option, provided we can rearrange and re-bend the heat pipes to our desired locations, etc.
Revision October 2020
These revisions are based on the test results of the latest revision of the lights boards.
The prototype board with 4 red LEDs stabilized at 62 C. Current consumption was 500mA as expected. Ambient temperature is room temperature (generous estimate of 25 C).
Calculations are here:
| View file | ||
|---|---|---|
|
Board | Required resistance |
|---|---|
Front Turn Lights | 6.64 C/W |
DRLs | 0.53 C/W |
Side Turn Lights | 6.64 C/W |
BPS Strobe | 39.32 C/W |
Centre/rear brakes | 6.64 C/W |
Rear Turn Lights | 12.33 C/W |
It is worth noting that most of these lights (aside from the DRLs) will spend the majority of the time turned off. Thermal management may not be required for them at all.
Given our current dimension restrictions, this is the best that an off-the-shelf heat sink can do: https://www.digikey.ca/en/products/detail/assmann-wsw-components/V5619A/3511388
Fortunately according to the above calculations, a heat sink is not mandatory, but it may still be useful. It helps that the heat sink from the link above is very cheap so we can afford to experiment with it.