Heat Sink Fabrication via Radial Extrusion and Compression
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Solution Overview
Problem
Conventional heat sinks, such as extruded heat sinks, have limitations in fin length and spacing due to the extrusion process, leading to inefficiencies and higher costs compared to bonded or folded fin heat sinks, which also face challenges with thermal conductivity and labor costs.
Innovation Solution
A method for fabricating heat sinks with flared fins using a die and compression tool to produce parallel fins, allowing for longer, thinner fins spaced closely together, achieving a higher length-to-distance ratio and reducing production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional extrusion process is used to fabricate heat sink, then production cost is reduced, but fin length-to-distance ratio is limited to 10:1
Solution Approach 1:
The fabrication process is segmented into two distinct stages: first, extruding the heat sink with radial fins using conventional extrusion process; second, compressing the fins to achieve parallel configuration. This segmentation allows each stage to optimize for its specific function, resolving the contradiction between manufacturing simplicity and fin geometry flexibility.
Solution Approach 2:
The radial fin configuration is created in advance during the extrusion process, before the final parallel configuration is achieved. This preliminary action allows the extrusion process to focus on creating the basic heat sink structure, while the parallel fin configuration is established in a subsequent compression step.
2Length of stationary object
If bonded fin or folded fin heat sinks are used to achieve longer, thinner fins with higher length-to-distance ratio, then thermal performance is improved, but labor cost and fabrication time cost increase considerably
Solution Approach 1:
The invention merges the advantages of conventional extrusion (low cost, simple manufacturing) with the advantages of bonded/folded fin heat sinks (high fin length-to-distance ratio, improved thermal performance) by combining extrusion with a compression step that transforms radial fins into parallel fins, achieving both cost-effectiveness and high performance.
Solution Approach 2:
The fin configuration parameter is changed from radial to parallel through the compression process. This parameter change allows the heat sink to achieve the high fin length-to-distance ratio characteristic of bonded and folded fin heat sinks while maintaining the cost advantages of extrusion-based manufacturing.
3Ease of manufacture
If conventional extrusion process is used, then material cost drives the cost, but fin spacing and length are limited, leading to less efficient heat dissipation
Solution Approach 1:
The fin configuration is made dynamic by introducing the compression step that transforms the static radial fin structure into a parallel fin structure. This dynamic transformation enables the heat sink to achieve superior heat dissipation efficiency without sacrificing the cost-effectiveness of the extrusion process.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method results in heat sinks that are more efficient and cost-effective, comparable to bonded or folded fin heat sinks, with improved thermal performance and reduced material usage, suitable for forced cooling applications.
Implementation Method 1
extruding a blank of material through the die to produce the heat sink
Implementation Method 2
compressing the plurality of fins with a compression tool so that the plurality of fins extend from the base along planes generally parallel to each other
Implementation Method 3
attach convective heat sinks to cool these components, by providing an efficient heat transfer path from the devices to the environment
Implementation Method 4
transfer heat energy from the high temperature component to lower temperature of the surrounding air
Data Source
AI summary
A method for fabricating a straight fin heat sink (50) of the type having a base (52) and a plurality of fins (54) extending from the base is disclosed. Each fm (54) of the plurality of fins of the heat sink is spaced from one another a predetermined distance and lies along a plane generally parallel to planes of the other fins of the plurality of fins. The method includes: providing a die (20) configured to produce a heat sink (30) having a base (32) and a plurality of fins (34) attached to be base in a radial fashion about the base from at least one side of the base; extruding a blank of material through the die (20) to produce the heat sink (30); and compressing the plurality of fins (34) with a compression tool (40) so that the plurality of fins (54) extend from the base along planes generally parallel to each other.