How to Increase the Lumen in LED Headlight kit?

How to increase the lumen on led headlight bulbs the lumen result of led headlight bulbs? This relevant question is highly recommended everyday by manufacturers. We all wish to offer clients the brightest led headlight kit with best light beam. But how do we achieve that? What technical issue do we meet today? Here please allow me to explain to you.

Select top quality LED Chip for light source if you want to produce continuous high Iumen LED headlight bulb, which need to be high relative Iuminious flux and high temperature resistance. The initial choices are famous LED suppliers Iike Philips Lumileds, 0sram, Cree, Nichia, Sámsung and so forth. Their LEDs have exceptional performance and work very well at high temperature.

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

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

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

That means if you want to boost Luminious Flux, we need to control ambient temperature at within an acceptable range. Heat produced from LEDs at work. Heat dissipation is the key point.

Except led chip, additional electronics of led headlight light bulb will also produce heat at work, like IC driver, capacitance and so on. These electronics themselves could go up the ambient heat to 70 -80℃, if they are built-in led bulb, heat from consumer electronics and LEDs will combined and add up, temperature goes up too much. Now the reliable style is to produce a driver on outsidé built-in thése electronics. After that we only need to believe about how to reduce the ambient temperatures of LEDs

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

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


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


Second of all, Heat transfer from Resulted in PCB board and can continue transferring to light bulb body. With this process, PCB panel plays a major role. The very best PCB panel is copper foundation PCB, because the thermal conductivity of copper is the best. Aluminum foundation is accompanied by, the worst is glass-fiber panel. The surface of PCB board ought to be as even as possible for decreasing the gap between PCB table and bulb b


In addition, we use heat transfer silicone to complete the gap between PCB panel and bulb body, increase heat transferring. Cheap and good warmth transfer silicone are broadly different. Just like CPU warmth transfer silicone, you guys ought to know t


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


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


The shape of heat sink will affect heat dissipation performance. A larger surface of heat sink shall promote heat loss. Besides, airflow should be taken into consideration. The space between cooling fins isn't allowed to be as well narrow, or heat won’t dissipaté fast but transfér to additional cooling fins. Here we have a example, the Ebay led headlight below, there are therefore many cooling fins on heat sink plus they are very shut, space bétween fins are narrów, that's not good for heat dissipation. By comparison, you can observe the Philips 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 high temperature sink with large surface is better for heat dissipation, why dón’t we produce all led headlights with big heat sink? That is because there is limited space behind headlight housing in a few vehicles. Halogen bulbs are small size while led headlight is usually big size, when we replace it with a led headlight bulbs, space behind headlight casing may also be not enough in order that LED headlight can’t be installed on. So in practice, we are in need of the heat sink no more than possi


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


Passive Cooling TechonoIogy, so except active cooling, factories also offer another solution for heat dissipation, passive cooling, that's to equip a fan in led headlight buIb, cooling the buIb by fan. Thé passive cooling method is simpler and more simple. And we are able to make led headlight light bulb be small size along with high lumen result in this met


But it is a doubIe-edged sword to set up a enthusiast on led headlight bulb. The heat dissipation is relying on fan. If enthusiast has quickly short lifespan and stop running, led headlight bulb will shortly blow in. So the quality is vital. Now we generally use two types of fans, sleeve bearing enthusiasts and ball bearing enthusi


Sleeve bearing fan depends on lubricating oil to work. It really is low manufacturing cost, and operates fast with low noise [empty] at the beginning. After working for some right time, lubricating oil will volatilize, fan rotating speed will also drop significantly. Weather and working condition decide the lifespan óf a sleeve béaring lover, normally it can work six months to 12 months on a car led headli


Ball bearing fan is much better though more expensive generally. Based on the rolling friction transmitting and consisted of two ball bearings, there are some tiny metal balls in thé bearing, balls turn when their axis movements with little friction. Ball bearing supporters do not suffer the same restrictions of oil volatilizing as sleeve bearing supporters, are stronger at higher temperatures, and has longer lifes


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


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


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