Efficient Thermal Transfer: Fast-Track Gap Pad Development for LED Banks

Background 

A new customer reached out to PGC. They specialize in the design, manufacture, and distribution of products and services for several markets — including veterinary, livestock, poultry, and water testing. Among their products is a microscopy device, which features a bank of LEDs. These LEDs generate heat that must be managed to ensure proper lifetime and performance of the given device. Because of our engineers' proven track record with thermal shielding, they sought PGC for assistance. 

Challenge 

The device's LED bank generated heat that needed to be transferred effectively to a heatsink. Without effective heat management, the bank of LEDs and the overall device's lifetime and performance could be compromised. Additionally, material availability, cost, and timeliness were concerns presented to our engineers.  The design had to be prototyped quickly, as the client needed sample pads within a very short timeframe to validate performance.  

Solution 

PGC utilized our rapid prototyping. This process involves securing raw materials, cutting/converting them, and delivering sufficient samples for testing. Our engineers leveraged their prior experience with similar materials and direct supplier relationships to obtain expedited material delivery from overseas suppliers. We were able to then efficiently source a thermally conductive sheet product with the desired thermal conductivity (~2.2 W/m‑K) and thickness (2 mm). We custom-configured the sheet to produce 169 individual pads per master sheet. All of this was accomplished within the client's tight 2-week timeline. 

Results 

The prototype gap pads were delivered on schedule, allowing the client to perform evaluation and validation testing without delay. The material met our customer's performance expectations in terms of thermal conductivity, fit, and conformability. Most notably, the pad layout developed by our engineering team optimized material utilization, minimizing waste and reducing costs. This thoughtful design not only improved efficiency but also demonstrated the depth of expertise our engineers bring to every project. By sourcing a readily available solution that aligned with both performance and budget requirements, we not only met the customer's technical needs but also strengthened their confidence in our process. Thanks to PGC's engineering excellence and commitment to delivering the right solution at the right time, the project concluded with another satisfied customer.