Manufacturing Process
Folded fins are created by a progressive stamping method. The fins are then bonded to a base with thermally conductive epoxy, brazing, welding, or similar metallurgical bonds, to create a heat sink. An advantage of folded fin heat sinks is the ability to combine aluminum and copper to tailor the performance of the heat sink to the particular application. If the heat must be spread over a large heat sink base, copper can be used for its high conductivity, yet the heat sink fins can be produced from aluminum, due to its low weight and cost.
Materials
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Aluminum
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Copper
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.010″ to .032″ sheets folded into fins
Specifications
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24 in (609 mm) max profile width
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As low as 0.2 mm fin thickness
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Fin densities from 4 to 38 fins per inch
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Fin heights from .020 to 2.75 inches
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Airflow lengths are limited to 610 mm (24″)
Applications
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High density cooling of power modules
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IGBT’s or transistors
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Telecommunications
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Motor drives
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Automotive electronics
Benefits
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Lightweight
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Reduced material cost
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Forced airflow or natural convection
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High aspect ratio fins
Tooling Cost
Production Cost
Finishing
- CNC machining
- Drilling
- Tapping
- Stamping
- Anodizing
- Screen printing
- Powder coating
- Laser etching
- Polishing
- Embedded fans
- Thermal greases
- Screws
- Springs
- Clips
- Embedded heat pipes
- Phase change materials
- Back plates
- Gap filler pads
- PEMS
- Standoffs
- Dielectric pads
- Compounds
