Copper Heat Pipes

Copper heat pipes are made from copper and use water as the working fluid. These pipes typically operate between 20 to 150 degrees C. Such pipes can be manufactured in different “geometries” or shapes, such as tubular heat pipes and planar heat pipes. Diameters vary but typically fall between 1/16” and 1.5 mm and 1.5” or 38 mm, though custom diameters are possible based on a customer’s specific needs. Planar pipes can be used as heat spreaders.

Copper heat pipes can be combined with other components creating heat transfer assemblies. Some examples of such applications include: heat pipe sinks which are used for both energy conversion device cooling and electronics; embedded heat pipe heat spreaders, which cool electronics; and heat pipe heat exchangers, which cool electronics enclosures among other possibilities.

Regardless of your specific application for heat pipes or copper heat pipes in particular, the various types of heat pipe assemblies can be manufactured to your specifications to ensure the best results. As mentioned earlier, the diameter, cross section geometry, and length are all customizable. So are the length geometry (allowing for straight or multiple bends), bonding of heat piper to assembly (mechanical, epoxy or soldering), and surface coating (often nickel or tin). Contact your local company that specializes in copper heat pipes to get started on your project today. The company should be able to give you an idea of how long the project will take to complete as well as the total costs involved given your specifications.

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Extruded Aluminum Heatsinks

Extruded aluminum heatsinks, or aluminum heat sink extrusions, are a very common component used for heat management in electronics. Heatsinks in general are critical for cooling the systems of such products and provide huge benefits for commercial and electronic device manufacturers. Extruded shapes are typically more tolerant than machined parts, in addition to often being more cost effective.

Aluminum has a number of qualities that make it an excellent choice for meeting your heatsink needs. Aluminum alloys are typically very malleable when compared to other metals and can be used to create a wide variety of different heat sink designs. Aluminum is also lightweight but strong. Aluminum is both a good hear reflector and a good heat conductor, which makes it very useful as a reflective heat shield and for heat transfer applications.

Aluminum is thermally less conductive than some other metals, but the alternatives, like copper, are more difficult to work with. Aluminum is also easier to work with when creating custom aluminum heatsinks, perhaps with foil, fins, or sheets.

Extruded aluminum heatsinks and heat sink extrusions in general are often easier to make, allowing for faster turn-around time and lower total cost. When looking for a manufacturer for your heatsink needs, discuss price and well as the amount of time it will take to complete the project. Make sure you find an experienced manufacturer who can meet your specifications. If possible, ask for referrals and talk to other individuals who have utilized this company’s services.

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Different Challenges Addressed by Custom Heatsinks

Given the extraordinary prevalence of electronics in nearly every aspect of our daily lives these days, it’s no wonder the demand for custom heatsinks is so high. If you find yourself with a particularly difficult or unusual application for a custom heatsink, the following examples may be helpful to you when discussing your needs with a custom heatsink manufacturer.

If your electronic components are in need of cooling via natural convention rather than forced air cooling, this particular application is inherently more challenging. Without the air flow often provided by a fan, the thermal resistance of your heatsinks will likely be much higher, perhaps by as much as 20%. Without air flow, your custom heatsinks are dependent solely on what is called the “chimney effect.” To address this, your custom heatsinks must minimize friction between the metal surfaces of the heatsink and air while also providing enough surface area for enough heat transfer.

Heavily populated PCBs are more difficult to keep cool, and, as a result, custom heatsinks are typically needed to address the particular application. Significant airflow must be available across the PCB; if airflow is not properly managed, those heatsinks further away from the fan may not work as well as they need to, providing an opportunity for the components to overheat. Custom heatsinks for this type of application need to produce low pressure drop to maintain an appropriate airflow.

Though the variety of custom heatsinks is as great as it is because every application is slightly different from the next, hopefully these two scenarios will help you when considering your next application that requires custom heatsinks.

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BGA Heat Sinks and Folded Fin Heat Sinks

With the extraordinary variety of heat sinks available for various electronic applications. This article will define and briefly discuss two such examples: BGA heat sinks and folded fin heat sinks.

BGA heat sinks, or ball grid array heat sinks, have a printed circuit board (PCB) or laminated substrate. Electrical chip components are routed to an array of balls on the substrate bottom. These can range in size from a few millimeters to over 50 mm. Ball pitch is anywhere from 0.5 mm to 1.5 mm currently. The balls are typically on a rectangular grid though the grid can be square as well. The matrix populated by these balls may be either full or depopulated, terms which specify whether all available spots are filled or not.

Folded fin heat sinks, on the other hand, provide a high surface area in a small volume, which provides a high level of cooling. These heat sinks are comprised typically of one sheet of metal folded over and over in a particular pattern, creating those folds and large surface area. Folded fin heat sinks can be made in a number of different styles, from many different materials and with different fin densities. These can be used with or without a fan.

As mentioned earlier, heat sinks have an extraordinarily broad array of applications thanks to the broad range of electronics. BGA heat sinks and folded fin heat sinks are only two examples of the wide range of heat sinks available to address the problem of temperature management.

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Heatsinks: Purpose and Design

Today’s computers continue to become faster and faster, but that speed coupled with the millions of calculations done in the blink of an eye generate heat that can threaten to destroy the processor itself. Heatsinksprevent this from happening by dissipating the heat as it is produced. These are necessary for all modern CPUs. Custom heatsinks offer solutions to the problem of heat on your own processors used for various applications. Custom heatsinks can be made from different metals, such as copper or zinc alloys, and can vary in size according to the needs of the specific processor. The addition of fins or metal slices on a custom heatsink increases the surface area of the heatsink, allowing for more efficient heat loss and dispersion. The addition of a fan can help further with the issue of overheating; those with a fan are considered active heatsinks, while those without are passive heatsinks. 

A heatsink manufacturer can work with you to design the perfect heatsink to keep your processor cool. You’ll need to work with the manufacturer to determine appropriate mounting style and heatsink material (which particular metal alloy is the best fit). The fins style can be varied as well. Don’t forget to work with the manufacturer to determine appropriate thermal resistance and well as the length, width, and height of your custom heatsinks.

Extruded heatsinks are most commonly used. To create these, the appropriate metal alloy is extruded through a steel die into the appropriate shape. Typically extruded heatsinks are initially very long “sticks” that are stretched and hardened before being cut into the final length prior to final secondary fabrication “touches.” 

If you are in need of custom heatsinks, contact a heatsink manufacturer to design the appropriate heatsink for your thermal management needs. 

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How Your Heatsink can be Customized

In need of custom heatsinks for temperature management? All CPUs need heatsinks to prevent them from overheating. This is done by increasing the surface area of the heatsink through various shapes and designs to allow for greater heat loss to the air (or water, depending on your application). The proper heatsink can reduce or entirely eliminate the need for a fan in your application.

Heatsinks may be made from different metals or metal alloys depending on the nature of your temperature management needs. These options typically include copper, nickel, or aluminum by themselves or as alloys. Each of these metals and their alloys has different properties which will help determine which is right for your application.

Heatsinks may or may have have fins to further increase surface area to promote heat loss. The possible designs for these fins is infinite. A heatsink with a pin fin, for example, fas the option of cylindrical, elliptical, or square pins. Those pins may also be straight or flared, again depending on your application. Many other types of fins are possible and available for manufacture.

Heatsinks may be treated with a surface treatment or different finish option as well. Work with your custom heatsink manufacturer to determine which option and specific finish or treatment is right for your application.
Custom heatsinks need to be mounted to complete the job they are needed to do. There are a number of different options for mounting your heatsink; Smartclip and socket clip are two such options.

When choosing a custom heatsink manufacturer, consider the total cost, time to completion, available surface treatment/finish options, packaging options, and, of course, options available for your custom heatsinks. Some manufacturers even have online tools to design your heatsink.

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Custom Heatsinks for Optimal Results

If your business requires using a heatsink, you know how critical it is to find the right company to provide you with reliable merchandise, on time, and with globally competitive pricing. But what if you cannot use a heatsink that is readily available, but require something customized? Here are a few hints to help you find the right manufacturer.

Since you already have determined that a stock variety of heat sink will not work, have you figured out exactly what you need? Finding a company that has a staff of design engineers is critical, because even if you think you know what your requirements are, there might be a key factor missing in your design. It is always better to find that out before you commit too many of your hard earned dollars to squander on something that will not do exactly what you want. Not to mention the time, effort and energy you will have lost. Production time will be lost as well, and if your bottom line is time and date stamped, better avoid those costly delays.

Any company that you are considering should offer a complete thermal analysis for you, and offer a wide variety of materials to choose from. Some applications do best with aluminum, while others use copper. A good manufacturer can explain the pros and cons for each, show the costs for both, as well as delivery time. Information that will be critical for you when it is time to make a decision.

If you are located in the Livermore CA area or the San Francisco Bay area, you are lucky because there are companies that fit every part of this bill. And since these companies also deliver their products to a global market, location is not as important as it used to be.

Don't let what is on the market now in heatsinks stunt the creativity of your design team. Find a heatsink manufacturers who will customize the perfect solution for you, and go to the head of the line in manufacturing using a custom heatsink.

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Cooling Sources in Electronics

What are Heat Sinks? In electronic devices, heat sinks are heat exchangers that are placed in different electronics and computers. To keep the whole device cool is the only function of a heat sink. There is a wide range of heat sinks, including forced or natural air cooling heat sinks and water coolers.

Active and passive are the two varieties of heat sinks. Heatsinks are made keeping in mind the heat a device produces. This heat needs to be absorbed to keep the device and its systems cool and functional. An aluminum extruded heat sink is the most common and most cost-effective means of providing the necessary cooling mechanism in an electronic device. 

Heatsinks are also provided with custom designs and features as effective cooling sources for different electronics. Some of the heat sink types are: 

• Skived fin heat sinks

• Folded fin heat sinks

• Bonded fin heat sinks

• Die cast heat sinks

• Stamped fin heat sinks

The CPU Cooler and its Function

In a CPU, the cooling system is of immense significance. CPU coolers are designed to dissipate the heat produced by different components working constantly in the unit. This type of air flow helps to moderate the temperature in any electronic device that produces excessive heat.

Failure of your CPU cooler can result in a problem like permanent damage of the device. Therefore, it is extremely important to have a close look at the cooling sources of any device to monitor whether or not they are working properly.

Fans of various sizes are placed in large computers to remove heat. This placement of exhaust fans in computers varies from model to model. Parallel and series installations of fans as cooling means in CPUs are the most common setups. Moreover, heatsinks are the most commonly used cooling sources that contain fins to offer the maximum cooling surface area to make contact with the air. 

There are many kinds CPU cooling sources, which include: 

• Active cooling sources

• Passive cooling sources

• Water and heat pipe cooling sources

• Exotic cooling sources

Liquid Cooling vs Heat Sink

Liquid cooling systems involve coolant-filled tubes, radiators and water blocks to keep the computer cool during excessive work. This setup sometimes includes a fan to help move around the water. However, in most computers, a heat sink is used to draw heat from the processing units. 

In some cases, heat sinks have proven inefficient in cooling computers. A device that produces excessive heat usually contains a liquid cooling system. This is mainly because water is an extremely efficient thermal conductor. Moreover, water can absorb more heat than heat sinks. In more expensive and advanced CPUs, the quality of the cooling source cannot be compromised. Therefore, the devices contain the most efficient cooling systems to make sure that heat produced in the processing units is being removed properly and efficiently. 

The effectiveness of liquid cooling technology, therefore, is preferred in modern computers and electronics. Liquid cooling means offer advantages, such as: 

• Efficient cooling boost

• Reliable for bigger, more advanced machines

• Preferable over traditional cooling sources 

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