High Power LED Street Light Aluminum Heat Sink Back Cover

Project Summary

The customer’s new 200W high-power LED street light originally adopted split spliced heat dissipation structure, splice gaps blocked heat conduction, leading to excessive chip temperature rise and severe light decay under long outdoor operation. Generic die-cast heat sinks on market had sparse ribs with insufficient heat dissipation area, plus offset mounting holes causing poor sealing & water short circuit risk. We adopted A380 die-cast aluminum alloy, designed integrated radial dense cooling rib structure, optimized mold exhaust & CNC precision hole machining, matched with grey matte weather-resistant coating. The finished part greatly improves overall thermal conductivity, reduces light decay and meets IP65 waterproof assembly tolerance, suitable for long-term municipal outdoor exposure with stable mass delivery.

Core Pain Points

1. Spliced gaps of split heat sinks block heat transfer, high temperature accelerates LED light decay and shortens lamp service life
2. Generic heat sinks have few uneven ribs with limited heat exchange area, failing cooling standard under high-power load
3. Numerous casting pores cause coating bubbling & peeling, rainwater penetration leads to power short circuit outdoors
4. Poor mounting hole precision creates assembly gaps, breaks waterproof structure and raises municipal maintenance cost

Custom Solution

3.1 Material Selection

A380 high-pressure die-cast aluminum alloy has excellent melt fluidity for one-step forming of radial dense thin cooling ribs. Its thermal conductivity outperforms plastic & ordinary cast aluminum, mechanical strength resists outdoor wind impact, and good coating adhesion delivers anti-UV aging performance for all-weather road lighting environment.

3.2 Structure & Mold Optimization

1. Uniform radial dense integrated cooling ribs maximize heat exchange area, rapidly dissipate LED heat and restrain light decay
2. Thickened outer sealing frame with unified fitting datum & precise locating holes realizes gap-free IP65 waterproof assembly
3. Full-area vacuum mold exhaust system with multi-point vents along rib roots & central cavity eliminates pores fundamentally
4. Uniform CNC stock allowance & single-clamping hole boring guarantee positional tolerance of all mounting holes

3.3 Core Process

Process Route: A380 aluminum melting → vacuum high-pressure integrated die casting → vibratory gate flash removal → CNC tapping & datum milling → sandblast pretreatment → outdoor weather-resistant electrostatic coating → waterproof assembly simulation test & packaging