LED Array Heat Spreaders

Name: LED Array Heat Spreaders | LED Thermal Management Plate - Frigate
Price: 249.00 USD
Availability: InStock

LED Array Heat Spreaders reduce thermal gradients across dense LED arrays. Uneven temperatures between emitters can shift wavelengths and cause color inconsistency. Phosphor aging also accelerates in hot zones. The LED Array Heat Spreader uses materials like pyrolytic graphite or vapor chambers to spread heat evenly. This stabilizes junction temperatures and preserves color uniformity.

Material Specification

Aluminum 6061-T6 (AMS 4025), Copper C110 (ASTM B152), Graphite Composite (ISO 18753)

Dimensional Tolerances

±0.05mm (Critical Features), ±0.1mm (Overall Profile), Thickness – ±0.02mm

Flatness/Coplanarity

≤0.02mm/m (Mounting Surface), ≤0.05mm (Overall Flatness), TTV ≤0.01mm

Surface Finish

Ra ≤0.8µm (LED Contact), Ra ≤1.6µm (Non-Critical), Bead Blast (Optional, Ra 3.2µm)

Thermal Conductivity

Al – 150-180 W/m·K, Cu – 380-400 W/m·K, Graphite – 300-500 W/m·K (In-Plane)

Product Description

Driving LEDs at high current increases junction temperature. This lowers light output and shortens LED life. The LED Array Heat Spreader reduces total thermal resistance between the die and the heatsink. Thermal resistance can go below 0.15°C/W. This allows faster heat transfer and keeps junction temperatures within safe limits.

Mounting Hole Specifications

M2-M6 (Metric), ±0.02mm Position Tolerance, Counterbore Depth – ±0.01mm

Burr-Free Requirement

Zero Burrs (ISO 13715), Edge Radius ≤0.1mm, Visual Inspection at 10x Magnification

Cleanliness Requirements

Particle Count ≤5mg/m² (ISO 16232), No Residual Oils (IPA Wipedown), Ionic Contamination <1.0µg/cm²

Protective Coating

Hard Anodized (Al, MIL-A-8625 Type III), Nickel Plated (Cu, ASTM B733), Anti-Oxidation Coating

Certification Standards

ISO 9001, RoHS/REACH Compliant, UL 94 V-0 (Flammability), IPC-7095 (Thermal Management)

Technical Advantages

LED modules experience thermal expansion during on-off cycles. Different CTE values between PCB and housing create mechanical stress. The LED Array Heat Spreaders uses CTE-matched materials like Cu-Mo or AlSiC. These materials reduce stress at solder joints and prevent delamination. Long-term structural integrity is maintained even during frequent thermal cycling.

Some lighting designs limit airflow. Sealed or compact housings restrict convection-based cooling. The LED Array Heat Spreader improves thermal spreading without increasing system height. Thin spreaders—under 0.5 mm—enable two-dimensional heat flow. This helps maintain safe operating temperatures in low-ventilation environments.

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Industry Applications

Architectural Lighting Systems

LED Array Heat Spreaders manage thermal gradients in compact linear modules used in recessed, wall-wash, and cove lighting applications.

Automotive Exterior Lighting

Enables uniform thermal distribution in DRLs, headlamps, and signal assemblies operating under sealed, vibration-prone, and high ambient temperature conditions.

Aerospace Cabin Lighting

Maintains junction temperature uniformity across multi-emitter arrays in low-pressure, vibration-sensitive aircraft cabin illumination environments.

Medical Examination and Surgical Lights

Controls emitter temperature in high-lux, thermally dense LED arrays used in continuous-operation, sterile-field medical lighting equipment.

Machine Vision Illumination

Prevents hotspot formation in high-intensity strobe or backlight LED arrays critical for thermal consistency in optical inspection systems.

Industrial High-Bay and Flood Lighting

Supports thermal regulation of high-power COB modules operating at elevated heights with limited convective air movement.

Elimination of Hotspots in High-Power COB Arrays

High-lumen COB modules generate hotspots near central emitters. These zones face early lumen depreciation. The LED Array Heat Spreader draws heat away using embedded vapor cores or carbon layers. Surface temperature stays uniform. No single LED experiences excess thermal loading.

Contact resistance at TIM interfaces reduces thermal efficiency. Poor flatness creates thicker TIM layers and uneven heat flow. The LED Array Heat Spreader is machined to under 10 µm flatness. Surface roughness stays below Ra 0.8 µm. This reduces TIM thickness and improves thermal conductivity at both contact surfaces.

Having Doubts? Our FAQ

Check all our Frequently Asked Question

How does Frigate ensure thermal performance repeatability across high-volume LED Array Heat Spreader batches?

Fregatte maintains strict thermal conductivity control through raw material certification and process monitoring at each stage. Flatness, thickness, and bonding integrity are verified using non-contact metrology. Batch-level thermal resistance is validated using laser flash analysis. This ensures every LED Array Heat Spreader delivers consistent thermal behavior.

What CTE values can Frigate achieve in custom LED Array Heat Spreader designs for ceramic-based COB modules?

Frigate offers CTE-controlled materials ranging from 6 to 17 ppm/°C, suitable for alumina, aluminum nitride, or hybrid ceramic substrates. Materials like Cu-Mo and AlSiC are selected based on stack-up requirements. Custom spreaders are FEA-tested for thermo-mechanical reliability under thermal shock. This prevents substrate cracking or solder fatigue in cycling environments.

How does Frigate reduce interface thermal resistance in LED Array Heat Spreaders for direct-die mounting applications?

Frigate provides sub-10 µm flatness and <0.8 µm surface roughness across all critical interfaces. This minimizes the bond-line thickness of TIM or solder preforms. Nickel plating or Au flash finishing options are available for improved die attach compatibility. The result is a lower junction-to-ambient thermal path.

Can Frigate integrate multilayer spreader architectures for directional heat flow in asymmetric LED arrays?

Yes, Frigate designs multilayer LED Array Heat Spreaders using stacked graphite sheets, phase-change cores, or copper foils. Layer orientation and thickness are tuned for directional thermal diffusion. This is particularly useful in asymmetrical emitter layouts or edge-mounted heat sink geometries. Thermal anisotropy is modeled using in-house FEA tools.

How does Frigate validate LED Array Heat Spreader performance for sealed or high-humidity lighting systems?

Fregatte conducts environmental testing including 85°C/85% RH exposure, thermal cycling, and salt fog resistance. Spreaders are sealed with vapor barriers or coated for corrosion resistance. Material stack-ups are selected based on water vapor transmission rate (WVTR) data. This ensures long-term reliability in outdoor and sealed luminaire applications.

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