High Efficiency Extruded Aluminum Heat Sink For Power Devices
1. High temperature precision extrusion process: core forming, laying the foundation for heat dissipation
Integrated extrusion molding: After heating and softening the 6063/6061 aluminum rod, the integrated structure of the substrate and fins is extruded in one go through a 10000 ton extruder and customized mold. No splicing or welding, eliminating contact thermal resistance from the root, and improving thermal conductivity efficiency by more than 30% compared to riveting/inserting.
Ultimate controllable dimensional accuracy: It can accurately control the height, spacing, thickness, and cross-sectional shape of the fins, with small errors in fin perpendicularity, ensuring uniform airflow through the fin gaps, avoiding eddy currents and airflow short circuits, and increasing the utilization rate of heat dissipation surface area by more than 25%.
Flexible implementation of complex cross-sections: supports various tooth shapes such as straight teeth, oblique teeth, wavy teeth, needle shaped teeth, trapezoidal teeth, as well as irregular cross-sections with installation slots, positioning holes, and reinforcement ribs. It can be optimized according to heat source distribution, airflow direction, and installation space to meet the heat dissipation needs of different scenarios.
Efficient mass production, lower cost: The extrusion process is continuous molding, which can produce several meters long profiles in one extrusion, and can be cut as needed later. The production efficiency is more than 50% higher than CNC milling, stamping and other processes, and the cost of mass production is reduced by 20% -30%.
2. Subsequent precision machining process: improve adaptability and fit
Precision cutting+deburring: Using a CNC cutting machine to cut long profiles into customized sizes, combined with a deburring machine/sandblasting to remove burrs from the cut, avoiding scratching heat sources and installation components, while improving surface flatness.
CNC milling/drilling/tapping: For the needs of mounting holes, positioning slots, threaded holes, and irregular substrates, precise machining is carried out through CNC machining centers to ensure that the heat sink and heat source (chip, IGBT, power module) are tightly adhered, control the contact thermal resistance, and avoid the decrease in heat dissipation efficiency caused by poor adhesion.
Straightening+shaping: After extrusion, the curvature of the profile is corrected by a straightening machine to ensure the straightness of the finished product, avoid deformation affecting installation and airflow, and ensure the consistency of the batch product structure.
3. Surface optimization process: Enhance durability and heat dissipation efficiency
Hard anodizing process: Aluminum alloy extruded radiators undergo hard anodizing treatment, which increases their corrosion and wear resistance by more than 5 times; At the same time, the oxide film has a porous structure, which can increase the contact area between air and fins, enhance convective heat dissipation, and improve heat dissipation efficiency by more than 10%.
Sandblasting/wire drawing process: By sandblasting/wire drawing the surface, the surface roughness is increased, further expanding the heat transfer area; At the same time, it can customize matte, brushed and other appearance effects, balancing practicality and aesthetics, suitable for scenarios such as consumer electronics and high-end home appliances that require appearance.
Passivation process: For copper aluminum composite extruded heat sinks, the copper substrate is passivated to remove the surface oxide layer and form a dense protective film, avoiding the decrease in thermal conductivity efficiency caused by copper oxidation and blackening, and extending the service life.
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