Types of CPU Coolers

When constructing your custom computer build one thing you might not remember to carefully consider is your CPU Heatsink and cooler. Your computer’s processor works hard and heats up quickly if it’s not equipped with an adequate cooling system. Carefully examine these different types of CPU coolers available to determine which type suits your build the best.

Passive cooling

This is the most basic type of cooling system and relies solely on the Heatsinks. The Heatsinks takes the heat from the CPU and spreads it across a larger area. Thermal grease or compound is applied to the CPU before the Heatsink. It assists in creating thermal conductivity to pull the heat from the CPU. These are not recommended for newer or high-performance CPUs because they don’t provide enough heat exchange.

Active cooling

Active CPU cooling consists of a heatsink and fan. They are available in many configurations and sizes. Nowadays, they include heat pipes to allow for faster heat exchange to keep the processor cool during operation. The fan circulates the hot air to cool faster and more effectively than a passive system.

Heat pipes

Heating pipes function as conductors in heat sinks. They have a liquid inside that takes the heat from the CPU Heatsink spreader to evaporate the liquid and turn it into gas. After it cools down, the gas goes back to the side of the heat as liquids to do it all over again.

Water cooling

A water cooling system utilizes a radiator and coolant setup for more advanced cooling technology. This aggressive method is achieved by attaching a water block to the heat spreader on the CPU. The coolant can pass through via two different openings with tubes attached to create a complete system including a pump and radiator. Coolant cycles through the system and takes the heat generated by operating the CPU to the radiator. Water blocks also allow you to cool other elements of your build, such as your hard drives or graphics cards, which tend to heat up and need additional cooling under intense gaming or operating conditions. The primary drawback is that a leak could form and damage your other hardware. It’s also pricey and time-consuming to configure.

Selecting from the variety of CPU coolers available is just as important as choosing the other components. Analyze your needs and choose one that suits your budget and needs at the same time.

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The important of aluminum heat sinks

There are many applications for an Extruded Aluminum Heatsinks in various industries. For example, in the computer industry, a heat sink is used to pull heat from the component and dissipate that heat into the air so that it does not harm the electrical component. In several mechanical applications a Extruded Aluminum Heatsinks is used to wick the heat away from the component and keep it cool. A growing number of manufacturers are using an aluminum heat sink for their applications since aluminum is both lightweight and a good conductor for heat dispersion. Excessive heat that is allowed to build up on any of these components could result in system failure that could cause property damage or injury.

It is for this reason that a growing number of companies that want to increase the longevity of their products will make sure that the heat sink that they use is one that is an aluminum heat sink so not only will they cut down on costs from having it installed, but they can rest assured in knowing that the product will operate within temperature thresholds which will add to the life of the product.

The alternative is using a substandard material for heat dispersion which is a risky idea. This is because many businesses pride themselves on the quality of their product and if they use an improper heat dissipater they could not only damage their credibility, but they could also open themselves up to a slew of lawsuits which could end them up in court. This is not what most companies want so they know that aluminum is the best option for them to use when it comes to using heat sinks for their products and the extrusion process that is used in the creation of the component will allow for more even heat dispersion.

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Why a Copper Heat Sink is Often the Heat Sink of Choice

A heat sink transfers heat generated by a mechanical or electronic device to a medium such as a liquid coolant or air. From there, the heat is dissipated and allows the regulation of a device's optimal temperature levels.

A heat sink cools graphics processors or central processing units in computers. High-power semiconductor devices such as optoelectronics or power transistors have an insufficient ability to dissipate heat. A heat sink is used to moderate the temperature.

A heat sink maximizes the surface area that is in contact with the surrounding cooling medium. The heat sink performance is affected by factors such as 

• Surface treatment 
• Protrusion design 
• Choice of material 

Thermal interface material and heat sink attachment methods also affect an integrated circuit's die temperature. Thermal grease and thermal adhesive improve the performance of a heat sink by filling gaps between a device's heat spreader and the heat sink.

Copper Heat Sinks  

Many heatsinks are made of copper. A copper heat sink has desirable properties for thermally durable and efficient heat exchangers. A copper heat sink is an excellent conductor of heat. The high thermal conductivity of the copper heat sink allows heat, to quickly pass through the device.

Other desirable properties of a copper heat sink are

• Antimicrobial resistance 
• Biofouling resistance 
• Corrosion resistance  

A copper heat sink has about two times the thermal conductivity as that of an aluminum heat sink. The conductivity is faster and has more heat absorption than a heat sink made of aluminum. Uses for the copper heat sink include:

• Electronics 
• Geothermal cooling and heating 
• Forced air cooling and heating systems 
• Gas water heaters 
• HVAC systems 
• Solar thermal water systems 
• Power plants 
• Industrial facilities 

Copper heat sinks are more expensive than aluminum heat sinks and are three times denser.  They are skived and machined. Another manufacturing method is soldering the fins into the base of the heat sink. 

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Innovative Extruded Heat Sink Technology Allows Cooling Source to Meet the Demands Placed on the Extruded Aluminum Heatsink

A lot of research is being conducted to come up with low-cost manufacturing methods that will produce an extruded heat sink that incorporates more fins in small-sized heat sink packages. Aluminum is an excellent material for an extruded heat sink.
 
Inexpensive tooling is used to shape the fin details of an extruded aluminum heatsink easily. The surface area is limited by the extrusion ratio or the number of fins and the height. A Cooling Source extruded aluminum heatsink is a cost-effective solution for most electronic cooling applications. 

Extruded heat sink profiles allow engineers to start or select a design from a pre-tooled extruded heat sink profile. Applications can be for a range of electronic packages. The increased surface area of the complex fin profiles allows for greater heat dissipation while eliminating the time and cost of machining equivalent block aluminum shapes.

The continued advance in consumer electronics and the rapid growth of options for LED lighting bring increased demands for energy with a smaller footprint. Increased power can be detrimental to electronics. The new demands present a thermal management challenge. 

The Process  

Innovative new processes in aluminum extrusion improve the quality and speed of the extrusions. Higher ratio air-cooled heatsinks are produced that are especially suitable for power electronics and lighting industries.

The most common technology for thermal management of cooling power electronics modules is extruded aluminum heatsinks. Often the technology of manufacturing new products is more advanced than the products themselves. 
For extruded aluminum, understanding of the material is not enough for designers and engineers to take advantage of the versatility of aluminum. Cooling Source understands the appropriate extrusion process needed for the most efficient product or material solution.
 
Complex fin structures are created by forcing aluminum throw extrusion dies. The basic process uses extreme pressure to press aluminum billet logs through the dies to establish the length of extruded aluminum shapes or profiles.

Contact Cooling Source 

Email or call 925-292-1293 to be put in touch with an expert that has information about the high-performance extruded heat sink profiles used for aluminum extruded heatsinks or other aluminum applications. A custom aluminum extruded heatsink can be designed to fulfill your needs.

Standard sizes are available for easy manufacturing of prototypes. Upon request, custom profiles to meet specific requirements are available. Cooling Source experts show the benefits of a process to help clients decide which extruded heatsink works best for them.  

Extruded aluminum heatsink advantages include: 

• Most cost-effective solutions for most electronic cooling applications 
• High fin density that improves cooling performance 
• Lighter in weight than copper 
• More efficient than a stamped heat sink 
• Wide variety of customizable designs 
• Useful flat back components for power modules 
• Unique shapes geared for electronic power assembly use

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Cooling Source Strives to Make the Best LED Heat Sink

Light-emitting diodes know as LEDs are a solid-state lighting form. The typical LED light has a piece of material that serves as a semiconductor, an integrated optical lens that shapes the radiation pattern and an LED heat sink that dissipates heat and keeps the operating temperature of the semiconductor low.

Some of the advantages of LED lights include:

• Faster switching  
• Smaller size 
• Improved physical robustness 
• Longer lifetime 
• Lower energy consumption

When used effectively, LED lights have enough power for street and room lighting. They require more precise current and heat management than compact fluorescent lamps and traditional incandescent light. LED lights are relatively expensive.

The life expectancy and performance of an LED light are linked to operating temperature. The lower the running temperature of an LED is, the longer the operating life and the better the performance. A critical aspect of designing an LED light is thermal management to increase the lighting quality and durability.

A heat sink providing natural convection is usually the means of cooling LED lights. A honeycomb-configured heat sink has been proposed to cool LED lights. The heat sink has a larger surface area and less weight than an LED heat sink used previously.

Experimental tests and numerical simulations were conducted in the investigation of a honeycomb heat sink under natural convection conditions. The research concluded that honeycomb heat sink performance could be improved by increasing cell numbers, aspect ratios, and rub space ratio at the fixed radius of the cylinder.  Further applications and experimenting will determine if the honeycomb design is a viable technique for an LED heat sink.  
Cooling Source has an extensive portfolio of LED cooling solutions. Extruded LED heat sinks are designed for residential and commercial LED lighting. Efficient heat dissipation reduces the cost of LED lighting systems.

The frequency of replacement is minimized. Fixtures are allowed to operate at higher levels of power. The ongoing cost of operation is reduced. LED lighting is eco-friendly. The lights last much longer which further lower the cost of replacement and save time.

Cooling Source has a broad range of cooling technology designed especially for LED applications. The company uses custom design and LED heat sink solutions for many LED needs. The global LED industry is extremely competitive.

The competition brings new solutions and products to the market more efficiently and faster. Cooling Source focuses on research and development in the field of heat and heat transfer. The company excels in design and production of the LED heat sink for LED light cooling solutions.

As a research and development enterprise, they pay close attention to the needs of their customers. Call them at 925-292-1293.

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The Thought Process Behind Cooling Source BGA Heat Sinks

The aim of designing heatsinks is twofold. The heatsinks need to provide thermal conduction inside and thermal convection on the surface. Evolutionary methods have optimized heatsinks for specific tasks that make efficient use of material and energy.

Nature is a source of inspiration when developing new products. Think about the branched systems of leaf venation and human blood circulation. Both systems take in and transport matter while conserving materials and structural stability. Designs vary based on effects in the environment.

Many successful heat sink designs are based on the same principle. They transport and dissipate heat energy. The result is an efficient solution for the required task. Shapes and processes are in harmonic balance. The technical function of heat dissipation connects intrinsic design of the device for which it is used.

Cooling Source offers a wide selection of BGA heat sinks. Our specialty is providing mechanical attach solutions where heatsinks are connected to the chip without holes or adhesives in the printed circuit board (PCB). The attachment solutions are used for high-reliability applications.

Customers choose Cooling Source when they need reliable, cost-effective cooling solutions. Our BGA heatsinks are made from high-conductivity aluminum. They handle the most demanding applications. We have a variety of attachment options, shapes, and sizes from which to choose.

If a standard option does not meet the customer's needs, we have a custom design service that will. Some of the BGA heat sinks we carry include:

 Elliptical Fin BGA Heat Sinks

 Pin Fin BGA Heat Sinks

Straight Fin BGA Heat Sinks

 Elliptical Fin Heatsinks

Elliptical fin heatsinks are aluminum BGA heat sinks that are highly efficient cooling devices ideal for environments with linear airflow. They are an improvement on cross cut heatsinks that were simply plated fin heatsinks with extra cuts across the fin length. The aerodynamic fins of the elliptical shape make airflow efficiency easier. They are ideal when airflow is limited.

Pin Fin Heatsinks

Cooling Source offers pin fin heatsinks that are well-suited for applications where airflow comes from the top. Precision forged pin fin heatsinks come in passive and active versions. The pin fin heatsinks can be forged of copper or aluminum.

Straight Fin Heatsinks

These heatsinks have many base dimensions and heights up to 15 mm They are ultra-performance heatsinks that have a high aspect ratio. The design of the straight fin heatsinks is optimal for applications with adequate airflow. They offer excellent cooling solutions for PCB layouts that are spatially constrained.

The high-performance ensures a reliable life of the product at a cost lower than other extruded heatsinks. The extruded aluminum keeps costs down, reduces weight, and minimizes thermal resistance. Cooling Source has or makes all of these heatsinks and more. Call us at 925-292-1293.

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Creating Larger Aluminum Heat Sink Extrusions

With continued advancement in consumer electronics and rapid growing LED lighting options, new products require increased energy demands with a smaller footprint. Increased power can cause heat that is detrimental to electronics.

Dealing with that heat presents a thermal management challenge. The most common technology for electronic modules is extruded aluminum heatsinks. There are two categories of extruded aluminum heatsinks – high ratio and low fin.

The fin ratio compares the fin height to the width between the fins. Typically, extruded aluminum heatsinks have a ratio of 6:1. That ratio does not meet most power electronics requirements. The typical ratio needed ranges from 12:1 to 19:1.

A greater fin ratio indicates greater surface area. Greater surface areas mean larger amounts of heat can be removed. Specific technology and experience are required for heat sink extrusions with higher ratios. It's hard to find heat sink extrusions that are more than 24 inches wide.

Heat sink extrusions are thermal devices made of a solid piece of aluminum. Insulators are eliminated and make the heat sink extrusions more thermally efficient. Most heat sink extrusion applications use natural convection, eliminating the need for fans.

Bonded fin heat sinks that have a higher aspect ratio are common means to overcome the heat sink extrusion ratio limitations when higher ratios are required. Friction stir welding (FSW) offers a different approach.

It is eight percent more efficient and has more options. Combining FSW and the extrusion process, heat sink ratios that exceed 40:1 are possible. The combination allows for

Maximum flexibility regarding fin geometry and ratio

 The heat sink extrusions footprint

 Production of large scale heatsinks

 The custom extruded aluminum heatsinks replace bonded fin heatsink coil aspects. FSW is also used for liquid cold plates to seal them efficiently while allowing other features to be added to base plates at a lower cost.

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Copper Heat Sinks

Heat pipes are among the most efficient ways to move thermal energy or heat from one location to another. The typical uses of the two-phase systems are for cooling areas or materials. Heatpipes were first used in energy conversion systems to supply heat or remove heat waste. Today heatpipes are used in cooling and heat transfer in satellites, cell phones, and computer systems.

Copper heat pipes are designed for applications having gravity present thermal challenges or high heat loads. They are used when long life and reliability are critical. The rugged heatpipes have a sintered copper powder wick structure that withstands temperature and numerous freeze-thaw cycles ranging from -55° C to 180° C. 

Copper heat pipes operate flawlessly against gravity. Water is used as the working fluid in these heatpipes. The heatpipes move heat from its source to the point where it is managed more efficiently through liquid or air dissipation or radiated to space.

Copper heat pipes are typically incorporated into custom thermal solutions. They are integrated into customized metal cold plates or heat sinks to improve efficiency and effective conductivity. The integration allows thermal designers to improve the overall performance of a system.

The heatpipes can be integrated into extended surfaces, cold plates, and heat sinks through mechanical interference, solder, or epoxy. Copper heat pipes will last more than 20 years. Manufacturers have thermal solution calculator tools that help accurately predict and project how thermal solutions will perform. 

The calculators

Determine k-Core APG heat spread

Evaluate heatpipes for performance and sizing

Evaluate heat spread improvement for vapor chambers

Identify enclosure cooling options to meet target cabinet temperatures

The calculators easily and quickly determine the dimensions needed for the orientation and type of cooling fluid. The calculator helps achieve optimum performance from passive heatpipes for any application. They are used to determine the heatpipe size needed to attain a targeted thermal spread and conductivity in W/mK.

Technological Aspects of Pin Fin and Bonded Fin Heat Sinks

Pin fin heat sinks are part of a performance-oriented technology. They generate low drop pressure and exceptional cooling power. The omnidirectional system allows air streams to enter the array of pins from all directions.

Pin fin heat sinks are a flexible approach. The parts can be modified to fit specific requirements of an application. Characteristics of pin fin heat sinks include:

• Round pins that present minimal incoming air resistance
• Omnidirectional feature allows air streams to enter from any direction
• Extensive air turbulence generated by round pins
• Large surface area per volume
• Highly conductive alloy composition

The pin fin heat sinks are manufactured with a cold forging process. They are made out of copper and aluminum. Profiles for pin fin heat sinks can be square, rectangular, or round. They are RoHS compliant. Designs configurations include:

• Moderate
• Flared
• Splayed
• Sparse

Pin fin heat sinks are designed to maximize the surface area and for turbulent air flow induction near the pin fins.

Bonded Fin Heatsinks 

When the box gets too small, or things get too hot, bonded fin heatsinks increase the surface area without an increase in volume. Thermal resistance is reduced by a third to a half. Bonded fin heatsinks provide cooling for forced convection with 100 W of power or more.
Augmented surface bonded fin heatsinks reduce the overall thermal resistance by 15 to 25 percent. The option increases the air flow turbulence at the same time that multiple, short air channels are substantially increasing heat removal.

There are many benefits for thermal design engineers who choose bonded fin heatsinks over conventionally extruded aluminum heatsinks. The tightly controlled assembly technique increased the fin count which allows the manufacturing process to be independent of the base extrusion.
The process removes the limitation of conventional fin extrusion ratios dictated by the extrusion dies' steel strength. Bonded fin heatsink parts offer the highest possible fin ratios. They can be 30 to one or greater.

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Cooling Source Knows that Extruded Aluminum Heatsinks Are the Up and Coming Trend in Heat Sink Extrusions

Cooling Source continues to meet and exceed the expectations of its customers by delivering the highest quality heat sink extrusions at competitive prices. The superior engineering solutions are responsive to the needs of their clients.

They aggressively pursue improvement opportunities throughout the company's organization so that they can offer manufacturing expertise to all customers regardless of their size. The hope is to develop long-lasting relationships with their clientele.

Cooling Source supplies extruded aluminum heatsinks for a diverse set of industries. A few of the industries are:

• Automotive suppliers
• Military contractors
• Lighting component manufacturers
• Durable package goods providers

The commitment to quality assures each valued customer realizes the same level of customer satisfaction. Every effort is made to eliminate non-conformance in their process and promptly deliver every product order.

Extruded aluminum heatsinks are quickly becoming the new generation choice for aircraft and automobile components. They are in demand for ordnance products and many industrial and commercial can-shaped designs.

Cooling Source is well positioned for growth in the future. As the company continues to meet fabrication needs, it challenges the members of the organization to do more, faster and better. They know improvement leads to success for customers and strengthens relationships.

The dedicated staff of engineers assists in the development of an optimal design. Heat sink extrusions have a range of secondary operations. Cooling Source is striving to reduce the number of supply chain vendors required by their clients.

Formula for Success 

The depth of resources for extruded aluminum heatsinks is impressive. The highly qualified staff carefully cultivates business alliances with the use of CNC machining and in-house design and development tooling.

Cooling Source is proud of its past accomplishments. The company recognizes history is not a guarantee of future success. Attempts are made to anticipate market trends and formulate plans to meet implied needs.

The focus is on continuous improvement. Cooling Source continuously re-evaluates their processes to achieve technology advantages. They strive simultaneously to enhance quality and reduce costs that can be passed on to customers.

What Distinguishes Cooling Source from Its Competition

• Improvement of the manufacturing and overall prototype designs of extruded aluminum heatsinks
• Replacement of inefficient processes with techniques better suited for mass production
• Meeting challenging time-to-market requirements and deadlines
• Reduction in scrap that requires secondary machining
• Increase in the customers' profit margin

Types of clients they serve are companies outsourcing production of established items, companies exploring cost reduction design possibilities, and start-up companies. Call Cooling Source at 925-292-1293 for heat sink extrusion services and manufacturing capabilities.

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Extruded Aluminum Heatsinks from Cooling Source Are the Ultimate in Heat Sink Extrusions

It would be great to have someone walk into your place of business and meet all of your extruded aluminum heatsink needs. Cooling Source is the next best option. We have an extensive inventory of heat sink extrusions.

Any order can be fulfilled quickly. We offer both standard and custom extruded aluminum heatsinks. On our website, you can browse through our catalog of heat sink extrusions we have in stock. We have an online form for customers to use to request a quote with or without an existing heat sink. A customer representative will respond quickly.

Custom Heat Sink Extrusions

Benefits of custom heat sink extrusions include:

• Keeping tooling costs low
• Achieving a low per piece cost
• Little or no secondary machining

Heat sink extrusions are made in a variety of shapes. Each is designed to fulfill a particular need. Our Cooling Source experts can explain the benefits of a process and help determine which of our extruded aluminum heatsinks best fits your needs.

The advantages of extruded aluminum heatsinks are:

• Improved cooling performance provided by high fin density
• Lighter in weight than copper
• Work more efficiently than stamped heatsinks
• Cost less than machined assemblies
• Wide variety of customized designs
• Useful flat backs for power module components
• Geared unique shapes for electronic power assembly use

Time associated with the machination of an equivalent block aluminum form is eliminated

Extruded Aluminum Heatsink Finishes

Cooling Source offers finishes that protect heat sink extrusion parts against hazardous environments. For extruded aluminum heatsinks, we use an anodizing finish and chromate finishing. Anodizing is an electrolytic passivation process that increases the surface's natural oxide layer.

The finish is made of aluminum oxide. It is a sturdy finish that has excellent emissivity. Hard anodizing is implemented for high-temperature applications. The finish is electrically non-conductive. It is a low-cost option that is available in custom colors upon request.

A chromate finish is a conversion coating option that passivates aluminum. Chromate finishes are corrosion inhibitors. They prevent the extruded aluminum heatsinks from tarnishing. A chromate finish is electrically conductive. It is also a low-cost option that is available in yellow or clear.

We have earned the trust of our customers by offering service, reliability, and quality products. The world class customer service, extensive inventory, and the latest technology and engineering solutions are what we use to maintain excellence. Call us at 925-292-1293 for your in-stock or custom heat sink extrusions.

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Uses for Heatpipe-Assembly

Heatpipe-assembly offers solutions for thermal performance, help in the control of energy costs, and maximize the reliability and life of a system even under conditions that are harsh. When space is limited, a heatpipe-assembly is a compact thermal solution for cost-effective cooling.

A variety of heatpipe-assembly systems can be used to accomplish the task. The heat technology gives an effective means of moving heat for remote dissipation. Low thermal resistance heat spreads from isolated cooling or concentrated heat sources to protect applications such as:

• Military systems
• Transportation control systems
• Consumer electronic devices
• Computer components

When a system design makes it difficult to place a heating device adjacent to a critical component for essential cooling, remote dissipation thermal management is a solution.
Application Constraints that Benefit from Heatpipe-Assembly

• Space constrained by footprint or height – The height over an electronic module may be insufficient in the amount of space provide direct cooling at the location. Remote heatpipe assemblies can be effective solutions. When where is not enough room to increase the footprint or height of an existing heat sink, vapor or embedded chamber assembly may be the solution. When there is no restriction above the heat sink, vapor tower technology can be used. 

• Zero or limited electrical power construction – Natural convection cooling improves reliability and eliminates fan noise. A heat pipe will produce less noise than a large fan system when volume constraints limit natural convection cooling solutions. 
• Low maintenance – Electromechanical devices such as fans require maintenance and have a finite life. A heatpipe-assembly has no moving parts to fail. Maintenance requirements are reduced or eliminated. 
• Cooling in sealed enclosures – Electronics are sometimes sealed in an enclosure as protection from the environment. Heat needs to be dispelled to the outside of the housing. A heatpipe-assembly provides a thermal path to the wall of the enclosure. 

Any of the above constraints merit the use of a heatpipe-assembly.
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How Customization Affects Copper Heat Pipes

The data for the thermal conductivity that is published ranges from ten thousand to one hundred thousand W/m.K. This figure is between 250 and 500 times solid copper or aluminum thermal conductivity. 

These numbers are not reliable for most electronic applications. The conductivity of copper heat pipes varies greatly with the length of the heatpipes and to some degree with evaporator and condenser sizes, and the amount of transported power.

Heatpipes that are approximately 100 mm in length can achieve 10,000 W/m.K of thermal conductivity. A 200 mm length yields less than 33 percent of the 100,000 W/m.K thermal maximum that is typically published.

The calculation of the effective lengths of heatpipes is a function of the adiabatic condenser and evaporator lengths. The specified performance data for heatpipes is adequate for most standard applications but is limited for specific use.

The customization of heatpipes markedly affects performance and operational characteristics. Changing the internal structure of heatpipes, such as their wick thickness and porosity, allows tuning of heatpipes to meet specific performance features and operating parameters.

When the given heatpipe diameter needs to operate against gravity or at a higher power load, there needs to be an increase in the wick's capillary pressure. Higher power handling capacities require a larger pore radius.

To effectively work against gravity requires a smaller pore radius or increased wick thickness. Suppliers who specialize in the customization of heatpipes frequently use formulated copper powders or individual mandrels to meet the requirements of the product application.

Size is generally the most important factor with heatpipes. However, outward design changes such as bending or flattening degrade the performance of heatpipes. Gravity also has an influence. Copper heat pipes are capable of being flattened between 30 to 60 percent of their diameter.

The two significant performance limits for the application of heatpipes is the vapor limit and the wick limit. Flattening heatpipes alone does not degrade performance. Performance depends on the amount of excess vapor space available before heatpipes are flattened.

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The Need for LED Heatsinks

Not producing heat is frequently an advantage listed by LED users. That statement is only partially correct. A LED  feels cool to the touch because it does not produce infrared radiation (IR) heat. Without IR, a LED can be placed in areas that other heat sources would be problematic such as illuminating food, reef tank lights, and grow lights.

Though a LED feels cool to the touch, there is unwanted heat within the device. Inefficient semiconductors generate light and heat. Sixty to 95 percent of the power output is lost as heat. What is the solution to the excess internal heat?

LED Junction Temperature Management

It is crucial to use efficient thermal management to remove heat from high-power LEDs. Without good heatsinks, the internal temperature of LED junctions rises. The increased temperature causes the LED characteristics to go from good to bad. 

As junction temperature increases the lumen output and forward voltage decrease. Not only is the efficiency and brightness of a LED decreased, but the junction temperature affects the lifespan of a LED.  Catastrophic failure is not the usual outcome, but it can be.

Typically, the LED lumen output decreases over time. A higher junction temperature leads to faster deterioration. For that reason, LED junction temperature must be kept low. Using more current than rated drives the temperature high enough to cause permanent damage.

Heatsinks are necessary to LED lighting because they provide a path for heat to travel from a light source to an element on the outside. Heatsinks dissipate power in three ways.

Radiation - Heat is transferred from two bodies, having different temperatures, via thermal radiation.

Convection – Heat is transferred from a solid to a fluid that is moving, usually air.

Conduction – A solid to solid heat transfer occurs.

Materials Used for LED Heatsinks 

The thermal conductivity of LED heatsinks directly affects the heat dissipation efficiency. The price point of copper makes it a good choice. Aluminum is more widely used than copper. The majority of LED heatsinks are made of aluminum. Smaller LEDs can use thermoplastic heatsinks because the heat dissipation requirements are lower.

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