Professional High Power Cooling Solution Service Provider And Manufacturers

Large Heat Sink Manufacturing

Large Heat Sink Manufacturing

With the rapid growth of LED lighting options and the continued development of consumer electronics, new products tend to bing increased energy demand of each year, often taking up less space.This creates a thermal management challenge because the heat generated by the increased power can cause significant damage to electronic equipment, so we need to create large heat sink to dissipate the heat. Lori is a large heat sinks manufacturer of high power heat sink and a provider of high power cooling solutions. We have extensive experience in the manufacture and design of large heat sink. We can design and manufacture large heatsink with low price and good cooling effect according to customer's application and requirement.

Large aluminum heat sink is the most common thermal management technology used to cool power electronic modules, followed by bonded fin heat sinks and liquid coolers (also known as liquid cold plates), with each technology increased costs and complexity.

Large heat sink manufacturing technology options

Large heat sink manufacturing technology options included aluminum extrusion technology, skiving fin technology, bonded fin technology, friction welding technology. They all have their own features, advantages and applications.

Aluminum extrusion technology

In recently, an innovation in aluminum extrusion offers a new way to produce higher ratio air cooled heat sinks — heat sink ratios in excess of 40:1, and widths up to 800 mm.

Aluminum extrusion at its most basic is the process of pressing logs of aluminum billet under extreme pressure through steel dies to create lengths of an extruded aluminum heat sink profile. Innovation in large heat sink extrusions often takes the form of process improvements or metallurgy developments that improve the speed and quality of the extrusion. But a new process manufactures higher ratio air cooled heat sink from extruded aluminum heat sink profiles that can be particularly suitable for the led lighting and power electronics industries.

Extruded heat sinks are divided into two categories: low fin heat sink and high ratio heat sink. The fin ratio is the the height of the fin compared to the width of the fin. A typical aluminum extruder can provide a ratio of 6:1; However, this is not enough for most power electronics. At present, typical power electronics require ratios in the range of 12:1 to 19:1. The greater the fin ratio, the larger the surface area, the more heat can be removed.

Extruding higher ratio requires special extruding technology and experience. But it's hard to extrude very wide heat sinks, and it's almost impossible to find extruded heat sink that is more than 800 mm wide. But the advantage of an extruded heat sink is that the heat sink is made of a solid piece of aluminum without any insulation, which helps improve thermal efficiency. In addition, most extruded heat sink applications can use natural convection, which means no fan is required.

Skiving fin technology

High power heat sink average size is larger, so also known as large heat sink, large heat sink production technology requirement is high, customers can also choose to skiving fin technology, when a customer asked about the length of the skived heat sink, so skiving heat sink length can reach?

Lori heat sink production technicians to explain to you, the length of the skived fin heat sink theoretically can reach 3000mm, depending on the size of the skived fin machine, the technical personnel said, has not yet produced 3000mm skived fin heat sink, they have produced the longest skived fin heat sink for 1500mm, is used for large motor cooling. And the maximum width of heat sink fin is 500 mm, max height of heat sink fin is 140 mm. The longer the length of the heat sink, the thicker the base of the heat sink is required to be, otherwise it will be prone to deformation, of course, this is also affected by the material.

LORI has many skived machines, large skiving fin process is Lori independent research and development, through the machine transformation and process improvements, for high power skiving fin production was very skilled process, each year’s production of tens of thousands of sets of skived heatsink for all kinds of motor, large inverter, inverter and so on in the, has become the leading enterprise in the industry.

Bonded fin technology

When higher ratios are required for high power applications, bonded fin heat sinks (thermal epoxy or brazing) with higher finned aspect ratios are usually used to overcome the finned ratio limitations in extrusion processes (usually 19:1). Bonded fin heat sinks usually involve the use of thermal epoxy to bond the coils of aluminum to aluminum extruded pieces or plates. It is usually necessary to cut a groove into the plate, and then the connect the aluminum coil to the base.

Friction welding technology

Our friction stir-welding (FSW) modular heat sink offers a different approach, with a thermal efficiency 8% more than that of the bonded fin heat sink, and with more options, such as custom features that reduce assembly costs. Combining the extrusion process with the friction stir welding technology, we can achieve a large heat sink ratio of more than 40:1. The combination of FSW and extruder provides maximum flexibility in terms of fin geometry and fin ratia, while also reducing fin size and simplifying the production of large heat sink (30 inches width).The friction stir welding process is also used in liquid cold plate to seal them effectively while adding more features to the cold plate at a lower cost.

Advantages of friction stir welding technology compared with fusion welding technology include:

• Increased welding strength

• Homogeneous material, no filler metal or insulator in the material

• Enhanced impermeability -- completely nonporous, sealed joints

• The joint is flush with the surface

• Reduced thermal deformation -- there is only a small amount of thermal stress in the material, and therefore, a flat surface

• Higher repeatability -- production variables are few and easy to control, which also results in close tolerances

 Related Large Heat Sink 

Large heat sinks and liquid cold plates with Frivtion welding technology, large heat sinks with aluminum extrution, skiving, bonded fin technology.

A new method of joining metal surfaces

Friction stir welding is a solid-state bonding method that has been used in aluminum welding since the 1990s. It joins the homogeneous metal surfaces by the mechanical action of the rotating tool and produces a high strength, non-porous, homogeneous joint that does not degrade over time. Under the influence of pressure and heat, a new homogenous structure can be obtained without filling materials or insulators.

Instead of using thermal epoxy to manually join the aluminum coil to the aluminum base,  custom aluminum profiles replace the coil aspect of the bonded fin heat sink .They are welded together by friction stirring without the need for a separate base plate.

The process begins with the extrusion section, which includes the base and heat sink fin, which is held together by clamping and stamping. The heat sinks are permanently joined by FSW. Since the extrusion section can be any extrudable contour and size, there are fewer limits in the design. For example, these segments could be 10 inches high. This method not only produces widths up to 20 in. large heat sinks, but also very suitable for mass production, making these types of heat sinks competitive products in the market.

While the extruded heat sinks ratio is up to 19:1, many companies in the power industry require a larger ratios heat sink . At the same time, the LED lighting industry is looking for extrusions larger than the typical maximum extrusion width of 20 inches. Friction stir welding heat sink solves these two problems.

Comparison of friction stir welding module heat sink and bonded fin heat sink

The test results of FSW welding modular heat sink and bonded fin heat sink show that FSW technology has some improvement in cooling.The dimensions of the heat sink and the aspect ratio of the heat sink fin are designed to be suitable for extrusion and an extruded heat sink was used as the benchmark.The experiments were carried out in wind tunnels with a variety of airflow.The power resistor is used as a heat source.Thermal resistance, pressure drop and temperature distributions were obtained and compared.The result is an 8% improvement in thermal performance over the epoxy bonded fin heat sink while maintaining the equivalent pressure drop.

An 8% increase in thermal efficiency offers power electronics designers two options.The first is the ability to increase the power generated by electronic devices without increasing the size of the heat sink.The second is to reduce the size of the FSW heat sink by 8% and still provide the same thermal management. Both options help reduce the cost of the heat sink.

The increase in thermal efficiency gives the power electronics designer two options. The first is the ability to increase the amount of power the electronics generate without increasing the size of the heat sink. The second is to decrease the size of the FSW heat sink by 8% and still provide the same thermal management. Either option helps reduce the cost of the large heatsink.

In many cases, the technology to manufacture a new product is even more advanced than the product itself. In the case of aluminum extruders, knowing of the material alone is often not enough for engineers and designers to take full advantage of the versatility of aluminum. It is also important to understand innovative processes (such as friction stir welding) and the development of alloys and extrusion processes to properly choose the most effective material or product solution.

Expand the technology of friction stir welding to develop solutions in the field of thermal managementFriction stir welding technology is not new. It has been used by different industries for years.It is not well known because it is a proprietary licensed process and uses automation equipment that is not normally available in traditional welding workshops. This innovation is driven by the expansion of friction stir welding technology to develop solutions in the field of thermal management to produce large heat sinks with low price and high performance, which offers exciting answers to a big challenge for the power electronics industry.

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