Heatsinks and Metal Choice

If you find yourself reading this article, you likely are well-versed in the world of electronics and are yourself involved in the design of electronic systems. If you somehow arrived here and that does not apply to you, here is a brief crash course in the course in the world of heat sinks.

When you think about any kind of electronic item, whether that's your computer or the Christmas lights you use each winter or the video game your child simply will not put down, heat is a constant concern. Perhaps you've noticed one of these items or something similar becoming hot during use! Heat management is crucial for all electronics, and heat sinks are one of the primary ways to address this problem.

Heatsinks come in an infinite number of different designs and have pins or fins or other attributes meant to increase surface area and successfully manage the heat created by the electronic device in such a way that the device doesn't fail. Meta typel is a crucial decision when considering the best heat sinks for your application. Heat sinks exist in aluminum or copper or even different alloys. Though copper heatsinks are very popular, the other types of metal are as well.

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Where a liquid comes in contact with the hot heatpipe

Heat pipes are devices used for heat transfer that combine two principles: phase transition and thermal conductivity. These principles are combined in order to manage the transfer of heat that takes place between two solid interfaces. Where a liquid comes in contact with the hot heatpipe, this liquid turns into a vapor, which travels along the heat pipe until it reaches the cold interface where it condenses back into a liquid; this relseases the latent heat. The process repeats when the liquid then returns to the hot interface of the heatpipe again via capillary action or centrifugal force or gravity.

Heatpipes are very effective thermal conductors, though the specific thermal conductivity varies from heat pipe to heatpipe according to the length. Heat pipes typically are composed of a sealed pipe made of a material appropriate for the fluid that is being used. For example, copper is typical for water heatpipes, while aluminum is usually used for ammonia heat pipes. A vacuum pump is used to remove air from the empty heatpipe before a working fluid partially fills the heat pipe prior to sealing. Within the temperature range of the operating heat pipe, the heatpipe should contain both liquid and vapor.

Heatpipes date back to the advent of steam technology during the steam age, along with the “Perkins Tube” which was used widely in working ovens and train boilers. The term “heatpipe” wasn’t coined until 1963, when George Grover independently developed the technology at Los Alamos National Laboratory.

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Heat Sink Extrusions and Extruded Aluminum Heatsinks

Heat sink extrusions can have many benefits over other types of heatsinks. Here are some possible reasons why your application may benefit from the use of heat sink extrusions. Extruded heat sinks can be more efficient than stamped heat sinks. Fully machined assemblies are typically much more expensive than extruded heatsinks, which makes the extruded variety much easier on your pocketbook. Because many extruded heat sinks are readily available typically in many standard sizes and shapes, availability is likely to be assured. If your application requires customization, most heatsink specialists can readily accommodate such requests for heat sink extrusions. When considering particular metals, extruded aluminum heatsinks can have a significant advantage in terms of heatsink weight when compared to copper. Depending on the heat sink company you choose to work with, you may find one with types of mounting systems that eliminate the need for mounting tools and hardware specifically for that task.

Extruded heatsinks can be a better option than machined assemblies or stamped heat sinks. Heat sink extrusions can provide a broader range of solutions for higher powered systems and components. Depending on your needs for your specific application, complex fin structures are possible via extruded aluminum heatsinks when using raw aluminum and an extrusion die. The more complex fin structures can allow for greater heat dissipation via greater surface area, making the general task of heat management a much easier and cheaper one. Contact a specialist today to take advantage of all this!

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Introduction to Heatpipes

Heat pipes are devices used for heat transfer that combine two principles: phase transition and thermal conductivity. These principles are combined in order to manage the transfer of heat that takes place between two solid interfaces. Where a liquid comes in contact with the hot heatpipe, this liquid turns into a vapor, which travels along the heat pipe until it reaches the cold interface where it condenses back into a liquid; this relseases the latent heat. The process repeats when the liquid then returns to the hot interface of the heatpipe again via capillary action or centrifugal force or gravity.

Heatpipes are very effective thermal conductors, though the specific thermal conductivity varies from heat pipe to heatpipe according to the length. Heat pipes typically are composed of a sealed pipe made of a material appropriate for the fluid that is being used. For example, copper is typical for water heatpipes, while aluminum is usually used for ammonia heat pipes. A vacuum pump is used to remove air from the empty heatpipe before a working fluid partially fills the heat pipe prior to sealing. Within the temperature range of the operating heat pipe, the heatpipe should contain both liquid and vapor.

Heatpipes date back to the advent of steam technology during the steam age, along with the “Perkins Tube” which was used widely in working ovens and train boilers. The term “heatpipe” wasn’t coined until 1963, when George Grover independently developed the technology at Los Alamos National Laboratory.

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Ball Grid Arrays and BGA Heat Sinks

A ball grid array, or BGA, is a type of packaging used to mount a device like a microprocessor. They are used for integrated circuits. BGAs allow for the entire bottom surface of the device to be used rather than just the perimeter, while the leads are shorter on average which creates better high-speed performance. BGAs are made of many, many layers overlapping one another and can contain anywhere from one to one million of a variety of circuits, including but not limited to logic gates, multiplexers, flip-flops, etc. In general, ball grid arrays (sometimes mistakenly referred to as "bonded grid arrays") have high lead count, a remarkable effective density, and minimal inductance.

The BGA is derived from the PGA or pin grid array, which has a face covered or partially covered by pins which use a grid pattern. BGA packages can have an advantage over other packages due to a lower thermal resistance. Heat that is generated by the circuit flows more easily to the PCB or printed circuit board, which keeps the chip from overheating.

BGA heat sinks are available in multiple sizes for thermal management for low power applications. Like all heat sinks, BGA heat sinks can be customized and designed to your specifications according to your needs. Though some believe BGA stands for "bonded grid arrays," your custom ball grid arrays are sure to address whatever thermal management concerns your particular electronic device presents. Be sure that whatever company you decide on for your thermal management needs considers bga heat sinks for your application.

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LED Lights and Heatsinks

Have you ever been curious why LED lights aren’t as hot as other types of lights? Given the popularity of LED lights these days, especially as many of us put up Christmas lights prior to the upcoming holiday, it is quite fascinating to consider the way in which LED lights deal with the issue of heat dissipation and management as compared to other types of lights.

The variation in heat produced by different types of lights is quite drastic. As measured by one online retailer, a halogen bulb operated at 327 degrees. A CFL was cooler at only 167 degrees, but the LED was coolest by far at only 107 degrees. Heatsinks keep LEDs cooler than the competition, allowing for my toddler to handle the lights on our Christmas tree without me worrying that he’s going to burn his hands (and taking away the worry that the tree may catch on fire!).

Heatsinks in general work to dissipate heat for any kind of electronic and not just lights. LEDs, however, are a perfect example to provide which most of us are familiar with, as everyone knows how hot an incandescent light bulb can get. Heatsinks can be designed in a nearly infinite array with variations provided to meet the different needs of the application. LED heatsinks, like all heatsinks, can be made from different materials with different structures meant to maximize surface area to release heat more efficiently. Many heatsinks utilize pins, fins and other components for the general purpose of thermal management.

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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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