At present, the biggest technical problem of LED lighting fixtures is the problem of heat dissipation. The poor heat dissipation leads to the LED driving power supply and electrolytic capacitors, which have become the short board for the further development of LED lighting fixtures, and the reason for the premature aging of LED light sources.
At present, after the LED light source is powered on, about 30% of the electrical energy is converted into light energy, and the rest is converted into heat energy. Therefore, it is the key technology of LED lamp structure design to export so much heat energy as soon as possible. The heat energy needs to be dissipated through heat conduction, heat convection and heat radiation. Only by exporting heat as soon as possible can the cavity temperature in the LED lamp be effectively reduced, the power supply can be protected from working in a long-lasting high-temperature environment, and the premature aging of the LED light source due to long-term high-temperature operation can be avoided.
Let us follow the editor to see the heat dissipation path of LED lighting
Because the LED light source itself has no infrared and ultraviolet rays, the 40W LED down light source itself has no radiation heat dissipation function. The radiator must have the functions of heat conduction, heat convection and heat radiation
Any radiator, in addition to being able to quickly conduct heat from the heat source to the surface of the radiator, mainly relies on convection and radiation to dissipate heat into the air. Heat conduction only solves the way of heat transfer, while heat convection is the main function of the radiator. The heat dissipation performance is mainly determined by the heat dissipation area, shape, and the ability of natural convection strength. Heat radiation is only an auxiliary role.
Commonly used heat dissipation methods include die-casting aluminum radiator, extruded aluminum radiator, stamping aluminum radiator, plastic-clad aluminum radiator, and high thermal conductivity plastic radiator.
Die-cast aluminum radiator
The production cost is controllable, and the heat dissipation fins cannot be made thin, making it difficult to maximize the heat dissipation area. The commonly used die-casting materials for LED lamp heat sinks are ADC10 and ADC12.
Extruded Aluminum Heat Sink
The liquid aluminum is extruded through a fixed die, and then the bar is cut into a radiator of the required shape by machining, and the post-processing cost is relatively high. The cooling fins can be made very thin, and the heat dissipation area is expanded to the greatest extent. When the cooling fins work, air convection is automatically formed to diffuse heat, and the heat dissipation effect is better. Commonly used materials are AL6061 and AL6063.
Stamped Aluminum Radiator
The steel and aluminum alloy plates are punched and lifted by punching machines and molds to make them into cup-shaped radiators. The inner and outer peripheries of the stamped radiators are smooth, and the heat dissipation area is limited due to the lack of wings. Commonly used aluminum alloy materials are 5052, 6061, and 6063. The quality of stamping parts is small and the material utilization rate is high, which is a low-cost solution.
The heat conduction of the aluminum alloy radiator is ideal, and it is more suitable for the isolated switching constant current power supply. For non-isolated switching constant-current power supplies, it is necessary to isolate AC and DC, high-voltage and low-voltage power supplies through the structural design of the lamps in order to pass CE or UL certification.
Plastic-coated aluminum radiator
It is a heat-conducting plastic shell aluminum core radiator. The thermally conductive plastic and the aluminum heat dissipation core are formed on the injection molding machine at one time, and the aluminum heat dissipation core is used as an embedded part and needs to be machined in advance. The heat of the LED lamp bead is quickly transferred to the thermally conductive plastic through the aluminum heat dissipation core, and the thermally conductive plastic uses its multi-wings to form air convection heat dissipation, and uses its surface to radiate part of the heat.
The density of thermally conductive plastic is 40% smaller than that of die-cast aluminum and ceramics, and the weight of plastic-coated aluminum can be reduced by nearly one-third for the same shape of radiator; compared with all-aluminum radiators, the processing cost is low, the processing cycle is short, and the processing temperature is low; The finished product is not easy to break; the customer-owned injection molding machine can carry out the differentiated shape design and production of lamps. The plastic-clad aluminum radiator has good insulation performance and is easy to pass safety regulations.
Lightweight and cost-effective, they support sleek, modern lamp designs while simplifying installation with non-conductive surfaces (reducing electrical safety risks). The coating also offers design flexibility, with customizable colors to match fixture aesthetics. Suitable for mid-to-low power LED lighting (e.g., bulbs, small panel lights, and decorative fixtures), plastic-coated aluminum radiators strike a practical balance between thermal performance, durability, and cost-efficiency. They are particularly valued in commercial and residential projects where corrosion resistance and safety compliance are key requirements.
High thermal conductivity plastic heat sink
High thermal conductivity plastic radiator is an all-plastic radiator, its thermal conductivity is dozens of times higher than ordinary plastics, up to 2-9w/mk, with excellent heat conduction and heat radiation capabilities; it can be used in new types of various power lamps. Insulation and heat dissipation material, can be widely used in various types of LED down lamps from 1W to 200W.
The high thermal conductivity plastic radiator can be designed with many precise cooling wings. The cooling wings can be made very thin, and the heat dissipation area can be expanded to the maximum. When the cooling wings work, air convection is automatically formed to diffuse heat, and the heat dissipation effect is better. The heat of the LED lamp bead goes directly to the heat dissipation fins through the high thermal conductivity plastic, and dissipates quickly through air convection and surface radiation.
High thermal conductivity plastic heat sinks are lighter in density than aluminum. The density of aluminum is 2700kg/m3, while the density of plastic is 1420kg/m3, which is almost half of that of aluminum. Therefore, the weight of a plastic radiator of the same shape is only 1/2 of that of aluminum. Moreover, the processing is simple, and the molding cycle can be shortened by 20-50%, which also reduces the power of cost.
High thermal conductivity plastic heat sinks emerge as a cutting-edge solution for LED lighting, blending the advantages of plastic's design flexibility with enhanced thermal performance. Engineered with advanced composite materials , these heat sinks deliver thermal conductivity far exceeding traditional plastics-effectively transferring heat from LED chips to maintain junction temperatures below 85°C, ensuring consistent luminous output, stable CCT/CRI, and a 40,000+ hour service life.
Lightweight and non-conductive, they eliminate electrical safety risks and enable sleek, complex fixture designs (e.g., curved profiles or integrated housings) ideal for decorative lights, small downlights, and portable LED fixtures. Their corrosion and impact resistance suit indoor IP40+ environments, while low production costs support mass manufacturing. Though optimized for mid-to-low power LED applications, their thermal efficiency rivals basic aluminum heat sinks in compact designs. Combining innovation, safety, and cost-effectiveness, high thermal conductivity plastic heat sinks are increasingly favored in residential, commercial, and consumer LED lighting projects seeking design versatility without compromising performance.
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