Jul. 29, 2024
A heat sink works by increasing the transfer rate of heat from the hot solid medium to a less hot or cool fluid medium. The heat sink achieves this with the use of pins or fins to increase the surface area and sometimes with the aid of a fan to increase the flow rate. The rate at which heat is dissipated is determined by the heat sink size, type, material, and location.
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Different devices need heat sinks to remove heat from areas that need to stay cool. Heat sinks will absorb and disperse heat from devices to prevent overheating. If an electrical component is not thermally managed then the internal resistance can increase while also leading to degradation of the materials, which in turn affect the performance and reliability.
There are six heat sink types that can be part of an active or passive system. They are commonly made of either aluminum or copper. The active systems use a fan to induce extra airflow over an area to improve cooling. The passive system relies on increasing the surface area of the component to allow more heat to be dissipated. Listed below are the types of heat sinks:
Bonded heat sinks are manufactured by using a conductive epoxy to adhere fins to a base. They can be made of either copper or aluminum or a mixture of both aluminum and copper. Bonded heat sinks are used for applications that require a high fin density. They have a much higher fin density than extruded heat sinks. This increased fin density is best used in an active system with forced airflow. The size of the bonded heat sink is virtually unlimited, and so they are generally used for applications that require very large heat sinks.
Skived heat sinks feature a series of tightly packed fins on a base that has been manufactured in one piece of metal which results in minimal thermal resistance. They are used in applications with high airflow and minimal space. This is the most cost-effective and reliable way of producing heat sinks. Skived heat sinks are made out of copper or aluminum. The maximum width of a skived heat sink is approximately 400 mm with a height of 200 mm. However, the length of the heat sink is only bound by the length of the copper bar that is used. Skived heat sinks have a dissipation capacity of around 1.5&#;2 times that of a bonded or soldered heat sink.
Extruded heat sinks are the cheapest to manufacture as the process involves extruding one long piece of metal continuously in a cross-section that forms fins and a base together. These heat sinks are used for high-powered semiconductor devices, and in medium to high airflow applications. While copper heat sinks can be extruded, most extruded heat sinks are aluminum. Extruded heat sinks are available up to a width of 400 mm and height of 60 mm. Since they are extruded, the length is unlimited.
Forged heat sinks are manufactured using compressive force to shape the metal. Forged heat sinks are usually made out of copper as it is more malleable which means it requires less heat to forge. They use either fins or pins to disperse heat. Forged heat sinks have low thermal resistance as there is no medium between the fins/pins and the base. They have a length and width of around 500 mm and a height in the 70 mm range.
A stamped heat sink is produced by stamping the fins out of sheet metal. The stamped metal fins are then held together using one or more zipper fins which are perpendicular to the normal fins and interlock to keep the distance. Stamped heat sinks are low performing, and so are used in low-power applications. The set of fins is usually soldered to the base. The size and geometry of the fins can be adjusted by using a different stamp.
CNC machined heat sinks are best used for one-time production requirements as they are not cost-effective to repeat and there are no extra tooling requirements for a one-off heat sink. Machined heat sinks are therefore used in bespoke, one-off applications. Copper is hard to machine, so machined heat sinks are mostly aluminum. The size of the heat sink will be limited by the capacity of the CNC machine used.
The main benefits of using heat sinks for different applications are:
The biggest challenge is that the performance of one heat sink type will vary depending on the environment in which it is used. Factors that will affect the choice of the heat sink are:
The best way to overcome these challenges is to use thermal-modeling software to predict which heat sink may be right, and then test it in real-world applications.
The main factors affecting heat sink performance are heat sink material, type, and location. If the material used has a high thermal resistance, it will not be an effective heat sink. So choosing a low-resistance material is key. However, the design can also increase thermal resistance if it uses a bonded or soldered joint between the base and the fins. The location and orientation of the heat sink will also affect its performance. Heat sinks should channel airflow parallel to the fins to maximize the surface area between the air and the heat sink.
The number of free electrons in a material will directly affect its ability to dissipate heat. The more free electrons, the better the heat will disperse, and the reason the two most used heat sink materials are metals. For more information, see our guide on What is Aluminum Alloy?
As the temperature of a device increases, its efficiency and reliability will decrease. This is because as the temperature increases so does the resistance. Therefore, to increase reliability and efficiency, heat sinks are used to moderate the heating effect.
Yes, a bigger heat sink can result in better thermal management. However, this will only be true if the right heat sink is selected for the application. Often, heat sinks are constrained by the other components around them, so a bigger heat sink is not always possible. In addition, a more efficient design of heat sinks may have better thermal management than one that is simply bigger.
Yes, heat sinks do need thermal paste to transfer heat from the component to the heat sink effectively. If thermal paste, or thermal paste substitute, is not used, the thermal resistance between the heat sink and the component is increased. This will negatively affect the heat sink performance.
No, heat spreaders do not work on the same principle as heat sinks. Heat sinks are used to transfer heat away from the component into a fluid medium, usually air but sometimes water or oil. Heat spreaders move the heat from the component to a large conductive body which has a similar effect but is not the same. Heat spreaders can be used in sealed units whereas heat sinks often use fans to move airflow over the heat sink. For more information, see our guide on What is a Heat Spreader?
This article presented heat sinks, explained what they are, how they work, and showed six things to consider when choosing one for your application. To learn more about choosing heat sinks, contact a Xometry representative.
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In electronics, effective thermal management is crucial for the longevity and performance of devices. Heatsinks play a pivotal role in dissipating heat away from critical components. While off-the-shelf solutions may work for some applications, there are instances where a Custom Heatsink is essential to meet specific thermal requirements. This article explores seven key factors when opting for a custom heatsink, ensuring you make informed decisions tailored to your needs.
Understanding the thermal performance requirements of your application is the first and foremost consideration. This involves determining the heat that needs to be dissipated and the acceptable temperature range for your components. Thermal resistance, measured in °C/W, is a critical parameter that defines the efficiency of a heatsink.
Calculating the thermal resistance needed involves knowing the component's power dissipation and the maximum allowable temperature rise. For example, high-power LEDs and CPUs have different thermal needs than low-power sensors. Ensuring your Heatsink manufacturer understands these requirements is vital to designing an effective solution.
The choice of material significantly impacts the performance and cost of a custom heatsink. The two most commonly used materials are aluminum and copper.
Aluminum: Known for its lightweight and good thermal conductivity, aluminum is a popular choice for many applications. It is also relatively cost-effective and easy to manufacture.
Copper: Copper has superior thermal conductivity compared to aluminum and is ideal for high-performance applications. However, it is heavier and more expensive.
Balancing these factors is crucial. A Heatsink factory can guide you in choosing the best material based on your thermal and budgetary needs.
The design and geometry of a heatsink directly influences its ability to dissipate heat. Different applications may benefit from designs like finned, pinned, or folded-fin heatsinks.
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Finned heatsinks: Increase the surface area for heat dissipation, making them practical for many general applications.
Pinned heatsinks: Offer enhanced cooling for high-power applications due to their increased surface area and airflow channels.
Folded-fin heatsinks: Provide a compact solution with high thermal performance, ideal for space-constrained environments.
When designing a custom heatsink, consider the available space, airflow characteristics, and thermal load. Collaborating with a Heatsink manufacturer can help optimize the design to meet your needs.
Various manufacturing processes can produce custom heatsinks, each with advantages and limitations.
Extrusion is suitable for high-volume production with relatively simple geometries. It offers a good balance between cost and performance.
Die Casting: Ideal for complex shapes and high-volume production. It provides excellent thermal performance but can be more expensive.
CNC Machining: Offers high precision and flexibility, making it suitable for low-volume, custom designs. However, it is typically more costly than other methods.
Choosing the proper manufacturing process depends on the design's complexity, production volume, and budget constraints. A Heatsink factory experienced in various manufacturing techniques can provide valuable insights into the most appropriate method for your project.
Attaching the heatsink to the component ensures effective thermal transfer and mechanical stability. Several standard attachment methods are:
Thermal Adhesives: These provide a simple and effective means of attachment, especially for small or irregularly shaped components. They ensure good thermal contact but may not offer the strongest mechanical bond.
Mechanical Fasteners: Screws, clips, and clamps provide a secure attachment and are suitable for more significant components or applications where strong mechanical bonding is required. They also allow for easy removal and reattachment of the heatsink.
Thermal Pads and Tapes: These balance ease of application and effective thermal transfer. They are often used in applications where frequent assembly and disassembly are necessary.
The choice of attachment method should consider the operational environment, mechanical stresses, and ease of assembly. Consulting with a Heatsink manufacturer can help determine the best method for your needs.
Environmental factors such as humidity, dust, and temperature extremes can significantly impact a heatsink's performance and durability. Therefore, it&#;s important to design with these conditions in mind to ensure long-term reliability.
Humidity and Corrosion: High humidity environments can lead to corrosion, especially in aluminum heatsinks. Protective coatings or anodizing can help mitigate this risk.
Dust and Debris: Dust accumulation can hinder heat dissipation by clogging fins and reducing airflow. Designs that minimize dust buildup or are easy to clean can be beneficial.
Temperature Extremes: Heatsinks in environments with wide temperature fluctuations must be robust against thermal expansion and contraction. Material choice and design considerations can help manage these stresses.
A Heatsink factory with experience producing heatsinks for harsh environments can provide valuable recommendations for protective treatments and design adaptations.
Balancing performance with cost is a critical aspect of selecting a custom heatsink. Several factors influence the overall cost:
Material Cost: Copper is more expensive than aluminum, but its superior thermal performance might justify the higher cost for high-power applications.
Manufacturing Complexity: Intricate designs or those requiring advanced manufacturing techniques like CNC machining can increase costs.
Volume of Production: Higher production volumes can reduce the cost per unit due to economies of scale.
Working closely with a Heatsink manufacturer can help optimize the design for cost-effective solutions without compromising performance. They can provide insights into the trade-offs between materials, designs, and manufacturing processes to meet your budgetary constraints.
Choosing a Custom Heatsink involves carefully considering multiple factors to ensure optimal thermal performance and reliability. Each step is crucial in developing a practical solution, from understanding your thermal requirements and selecting the suitable material to designing for environmental conditions and balancing cost.
Engaging with a knowledgeable Heatsink manufacturer can significantly streamline this process, providing expert guidance and tailored solutions to meet your needs.
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