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русскийCharacteristics of heat dissipation structure
Efficient heat conduction of metal substrate: LED chips will generate a lot of heat when working. If they cannot be dissipated in time, the chip temperature will rise, which will affect the luminous efficiency, color stability and life. 26W dual-beam LED headlight kits usually use metal substrates, such as aluminum substrates. Aluminum substrates have high thermal conductivity and can quickly conduct the heat generated by LED chips away from the heat source. Compared with traditional FR4 boards, aluminum substrates have obvious advantages in thermal conductivity. FR4 boards are mainly used for low-power applications. Although the heat dissipation capacity can be improved by adding vertical heat dissipation vias, due to the low copper foil content in the vias, its heat dissipation effect is far less than that of metal substrates. Aluminum substrates can transfer the heat generated by LED chips in the first time, providing a good foundation for subsequent heat dissipation links, and are the preferred solution for high-power LED modules.
Optimized design of heat dissipation fins: In order to further enhance the heat dissipation effect, the 26W dual-beam LED headlight kit is equipped with carefully designed heat dissipation fins. The function of the heat sink fins is to increase the heat dissipation area and promote the dissipation of heat to the surrounding air. These fins are usually made of metal, such as aluminum alloy, because they have good thermal conductivity and certain mechanical strength. The shape, size and layout of the fins are optimized. For example, the height, length and spacing of the fins are designed according to the principles of aerodynamics and heat conduction theory. By setting these parameters reasonably, the heat dissipation area can be maximized in a limited space, while ensuring that the air can flow smoothly between the fins to take away the heat. In some designs, the height of the heat sink fins in the middle position will be higher. This is because the temperature in the middle of the LED integrated component is relatively high through the temperature cloud map analysis. Increasing the height of the fins here helps to increase the intensity of convection heat dissipation and make the heat dissipation more uniform and efficient.
Accurate application of thermal conductive materials: In the heat transfer path, thermal conductive materials play a key connecting role. From the LED chip to the metal substrate, and then to the heat sink fins, the contact between the various components is not completely tight, and there is a certain air gap. The poor thermal conductivity of air will hinder heat transfer. Therefore, thermal conductive materials are needed to fill these gaps, exhaust air, and improve the efficiency of heat conduction. Common thermal conductive materials include thermal grease, thermal silicone and thermal pads. In the 26W dual-beam LED headlight kit, appropriate thermal conductive materials will be selected according to different application scenarios and needs. Thermal grease has the advantages of high thermal conductivity, good electrical insulation and a wide operating temperature range. It is usually used between parts that need to be frequently disassembled. It can squeeze out as much air gap as possible between the two parts of the zero-sticking to achieve the best heat conduction state. Its cured thermal conductivity can reach 1.1-1.5W/mK, which has a high guarantee for the heat dissipation coefficient of electronic products. Thermal conductive silicone is suitable for parts that require long-term stable connection. It has excellent electrical properties and aging resistance, resistance to cold and hot alternation, and can increase the service life of the product. Thermal pads have certain flexibility, good insulation and compressibility. They are specially produced for the design of heat transfer using gaps. They can fill larger gaps and complete the heat transfer between the heating part and the heat dissipation part.
Combination of active heat dissipation and passive heat dissipation: Some high-end 26W dual-beam LED headlight kits use a combination of active heat dissipation and passive heat dissipation. Passive heat dissipation mainly relies on metal substrates, heat sink fins and natural convection to dissipate heat, while active heat dissipation enhances the heat dissipation effect by introducing devices such as heat sink fans. The heat sink fan can accelerate the flow of air between the heat sink fins, so that the heat is taken away faster. In some designs, a dedicated microcontroller unit (MCU) is equipped to control the fan speed. The MCU can adjust the fan speed in real time according to the temperature of the LED chip. When the chip temperature is low, the fan runs at a lower speed to reduce noise and energy consumption; when the temperature rises, the fan speed increases to improve the heat dissipation efficiency. This intelligent control method can not only effectively dissipate heat, but also minimize noise interference during driving and enhance the driving experience. In addition, some kits may also use more advanced heat dissipation technologies such as liquid cooling systems to remove heat through the circulation of coolant to achieve better heat dissipation effects and ensure that the LED chip can work within the appropriate temperature range under various working conditions.
Durability design features
Anti-vibration and impact structural design: The car will inevitably be subjected to various vibrations and impacts during driving, which poses a severe challenge to the durability of the headlight kit. The 26W dual-beam LED headlight kit takes this factor into full consideration in its structural design. Its outer shell is usually made of high-strength metal alloys, such as aluminum alloy, which is both light and strong enough to effectively resist external vibration and impact. At the same time, the internal LED chips, metal substrates and other electronic components are installed in a special fixing method to ensure that they will not be displaced, loosened or damaged under vibration and impact environments. Some kits will use shock-absorbing materials or buffer structures to further reduce the impact of vibration on internal components, such as adding shock-absorbing materials such as rubber pads between components and the outer shell. These materials can absorb and buffer vibration energy, protect internal precision components, and extend the service life of the lamp.
Reliability design of the electrical system: The stability and reliability of the electrical system are crucial to the durability of the headlight kit. The 26W dual-beam LED headlight kit is equipped with complete electrical protection functions. In the circuit design, overload protection and short-circuit protection functions are set. When there is an overcurrent or short circuit in the circuit, the protection circuit will act quickly to cut off the power supply to prevent the LED chip and other electronic components from being damaged due to overcurrent or short circuit. At the same time, it has a reverse polarity protection function to prevent the lamp from being damaged due to the reverse connection of the positive and negative poles during installation. In addition, the heat-resistant cable used can withstand high temperatures, ensuring that the cable can still transmit current stably in an environment where the LED chip is heated, and will not cause insulation performance degradation or line damage due to excessive temperature, thereby ensuring the reliability and stability of the entire electrical system and improving the durability of the headlight kit.
Weather resistance and protection design: Car headlights are exposed to the external environment for a long time and need to withstand various harsh climatic conditions, such as high temperature, low temperature, humidity, salt spray, and ultraviolet radiation. The 26W dual-beam LED headlight kit is designed with full consideration of weather resistance and protection issues. The surface of the shell is usually anodized or coated for protection. Anodizing can form a hard and dense oxide film on the surface of the aluminum alloy, improve the corrosion resistance and wear resistance of the shell, and effectively resist the erosion of environmental factors such as salt spray and humidity. Coating protection can further enhance the shell's resistance to ultraviolet rays and prevent the shell from aging, fading or damage due to long-term ultraviolet radiation. In the sealing design of the lamp, high-performance sealing materials and processes are used to ensure that the interior of the lamp is completely isolated from the external environment and prevent dust, moisture and other pollutants from entering the interior of the lamp body. Even in humid environments such as rainy days or car washes, the internal electronic components can be kept unaffected and maintain good working conditions, thereby greatly improving the durability of the headlight kit in various harsh environments.
Selection of long-life components: In order to ensure that the entire headlight kit has a long service life, strict control is exercised on the selection of components. LED chips are used as core components, and high-quality, long-life products are selected. These chips have been strictly tested and verified in terms of luminous efficiency, stability and life, and can maintain good performance under long-term work. At the same time, for other electronic components, such as capacitors and resistors, products with reliable quality and stable performance are also selected. The use of these long-life components fundamentally guarantees the durability of the headlight kit, reduces lamp failures caused by aging or damage of components, reduces maintenance costs, and provides users with a more reliable and long-lasting lighting solution.
