Hunting for fan-cooled heat sink designed for LEDs that is under3 inches diameter

I am designing a small portable lighting system for puppeteers and other mobile performers like magicains. The emphasis is on the word small. Since I want at least a 10 watt LED, and preferably 20 watt, I realize I may need to go to active cooling.

I am looking for a fan-cooled heat-sink that is designed to be part of a well integrated system. By well-integrated, I mean a way to attach a lens and finish the housing some way, plus some guidance on how high a wattage a LED I can expect to use with a particular heat sink. The smallest such system I have found is the ø99mm IceLED Active Star LED Cooler by MechaTronics. I would prefer to stay under 3", and preferably as small as 2".

I realize I may be able to design such a system from scratch, using a fan-cooled heat-sink used for CPUs. But, I would certainly prefer to find something designed for LEDs and that has a housing I can use. Has anyone seen such a system as small as 2"?

-Joe

UPDATE, I have found yet another possibility. It uses a diaphragm type of air blower, and this model is around 2" Diameter. The fan itself is around $20/ea and then you must add the heat sink itself, at around $7/ea. However, it is not much different than using a CPU cooler, and drilling my own holes. I would prefer it if the heat sink itself formed the housing around the LED and lens.

http://www.aavid.com/led-cooling/mr16-led-cooler-heatsink-20w

-JOe

Look for LED coolers you can order from here http://www.digikey.com/product-search/en/optoelectronics/led-thermal-products/525429

You can find some of them suitable.
This one is 9$ and is intended to be used for 15W mr16 lamps http://www.digikey.com/product-detail/en/sunon-fans/LA001-002A99DY/259-1589-ND/3466809

For solution where the heatsink holds the led and the lens search for something like this http://www.digikey.com/product-detail/en/sunon-fans/SA000-12055/259-1683-ND/5014265
if you open the datasheet you will see that its hollow and you can put the led inside maybe even the lens.(some of them are designed to be used with specific LEDs and have holes and so on for easier assemble)

Unfortunately I'm not very experienced with these. Maybe some of the guys here can help you further.

Use axial blowers and chipset heatsinks with lot of fins - you can get very compact dimensions then.

Nichirenshu, thank you for the link to the Sunon SA000-12055 heat sink. However, I cannot find any literature that shows the specific fan that mates with it, or even to which end the LED is mounted. But, hopefully the deep end is where the LED goes. I have written the local representative to see if he can provide that information.

-Joe

cadcoke5 said:

Nichirenshu, thank you for the link to the Sunon SA000-12055 heat sink. However, I cannot find any literature that shows the specific fan that mates with it, or even to which end the LED is mounted. But, hopefully the deep end is where the LED goes. I have written the local representative to see if he can provide that information.

-Joe

Click to expand...

Plenty of passive pin fin heatsinks out there around 80mm dia good to 20 watts
Cheers
Welight

WeLight said:

Plenty of passive pin fin heatsinks out there around 80mm dia good to 20 watts
Cheers
Welight

Click to expand...

I haven't quite given up hope on getting something closer to 2" dia, and can handle 30 watts. If I can find an active solution at that size, I think it can handle the wattage.

When corresponding with my Sunon rep about the Sunon SA000-12055 (which is 85mm, =3.34" OD), I came across the Sunon SA000-12003, which is smaller, at 56mm, =2.20" OD and has a thermal resistance of 7.1℃/W passively cooled. However, they said that this is not designed to work with a fan, and the LED is designed to fit into the shallow end. Though, I can imagine the possibility of putting the LED into the deep end. However, none of this line has a fan option. But, for those interested, here is a link to their spec sheet on this family of heat sinks.
http://www.sunon.com/uFiles/file/04_application/LED Lighting/LED Lighting Thermal Module.pdf

Here is another interesting line. It seems to have a deeper LED mounting recess, and the cooling fins are supposed to be better with only ambient cooling.
http://www.heatsinkled.com/BuLED-50F-LED-light-accessory-to-replace-MR16-fittings-p45980507.html

-Joe