What is the most efficient method to mount a heatsink to an uneven surface?
I am converting all my lights to LED's they are cheaper on power and bulbs produce better light etc.. etc..
I just replaced 320watts of Fluorescents in a Display cabinet with 66watts of LED Tubes !! and they look Brighter and more evenly illuminated as a bonus!
Anyway I am finding out that one problem with LED's is heat. yes they produce far far less heat but it also takes less heat to DAMAGE them so I want to make a heatsink for them but therein lies the problem.
HOW do I mount it. ie what material do I use to interface the PCB with the Heatsink. go here
06 is a picture of the backside of the LED TUBE
07 is my drawing illustrating the problem. ie something has to go between the heatsink and the PCB (Red and Tan) I can not lap the surfaces for better mating like I can with a CPU since those solder nubs are required :-)
I have seen some CPU's mounted with what was more like double stick tape (not foamy though ie it was not "liquid" like artic silver is for example.) basically it was more solid than liquid but flexible enough to mate the objects.
Would something like that work efficiently ? IF so where could I get a large quantity of it (like a roll of it like a roll of tape thankfully these are pretty narrow about 3/4inch wide.
Basically I need to keep the led's below 85' F if possible or as best I can to extend there lifespans. These will run never ending at minimum 18 hours a day so they will not haver an opportunity to cool down. I want to retain the poly carb tube if I can in order to keep it airtight (the other danger with led's is the metal components corroding or rusting before the bulbs wear out) is there something I can POUR over the led's (the bottoms ie between them and the PCB to prevent moisture from getting to anything metal and how would this affect heat transfer ? I imagine if I use epoxy for example it would work great but actually act as an insulator increasing the heat problem. if I could protect it from water I would just discard the Polycarbonate tube all together further assisting heat dissipation. This is especially important for the outdoor tubes I want to use (protecting them from the elements) impact and direct element attack are not an issue they will be inside an enclosure. its humidity and condensation ie indirect moisture attack that concerns me. Also if I solve this for the outdoor sign led's I can then use the entire sign as one giant heatsink :-)
Any suggestions or help would be GREATLY appreciated!