Lights Thermal Calculations

Per the calculations in the document, we will need a fairly intensive cooling solution for a few of the lights.

Heatsink thermal resistance requirements can be found below. These calculations were done assuming a 400mA drive current 40 degree ambient, and 85 degree LED die max. 400mA is near the upper limit of adjustability. If we raised the current to 500mA, then the LED dies will reach around 95 degrees with these heatsinks.

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

Some useful terms explained here: https://ctherm.com/products/tci_thermal_conductivity/helpful_links_tools/thermal_resistance_thermal_conductance/

Heat pipes are used to move heat. Because of some of the small space constrained applications, we might need to use some (and I kind of want to have an excuse to use them).
There are some great resources below:

https://www.youtube.com/watch?v=I5CQsBWKtOg
https://www.youtube.com/watch?v=ezb3qRq3ACc
https://www.youtube.com/watch?v=eKrdJpDSowY

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.

Calculations are here:

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.