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In natural convection cooling, (passive air cooling) there is no forced air flow from a fan, blower, or any other source. The air surrounding the object transfers the heat away from the object.
The temperature of the air within the heat sink's fins increases due to heat from the heat source. The higher temperature air is less dense than the surrounding air and rises out of the heat sink. This movement will generate a small amount of airflow within the heat sink fins, cooling the heat sink.
Advantages include being inexpensive, easy to implement and easy to maintain. Baknor’s ability to identify the best possible heat sink solutions for your application includes resolving customer design issues to ensure the part can be manufactured reliably and economically.
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Start the conversation with our thermal design solution professionals, by using our thermal design check list, to analyze and solve your thermal challenges.
Extruded heat sinks are the most common heat sinks used for thermal management. They are one of the most popular and cost efficient heat sink fabrication methods.
Baknor’s extruded heat sink profiles range from very complex geometries to very simple flat back extrusions. Shortening fins or removing fins, as well as cutting can modify profiles or machining features as required.
Baknor continues to design tooling for new profiles, as they are often used to meet exact customer requirements. New profile tooling is cost effective in most requirements we work with today.
Custom Heat Sinks Made From Aluminum Blocks Machined, Castings And Forging
Custom Heat Sinks From Machining
A precision machined Heat Sink is a great choice for smaller production requirements as there are no non-recurring engineering charges (NRE). Baknor’s experts will work with you to optimize fin geometries and design the most efficient machined heat sink.
Machining offers a great degree of flexibility when you need intricate or unusual fin patterns or contours, cut-outs and through-holes to suit your unique and challenging applications
Custom Heat Sinks From Casting
Baknor’s thermal engineers are experts in designing heat sinks to maximize the advantages of die-casting.
Die cast heat sinks do not have the limitations imposed by extrusions from a 2-D profile nor the back pressure inherent in the saw cut, non-aerodynamic front end of an extrusion. An ideal solution when complex geometries are required.
Casted heat sinks are a cost-effective option for mid to high volume applications. Casted heat sinks are very effective when the application is weight-sensitive. Casting can also achieve superior cosmetic quality.
High Conductivity Casting is a melt preparation process for semi solid casting of components in high pressure die casting machines. The process was invented in Sweden and further developed over 10 years to achieve a stable, reliable and cheap process for high quality parts.
Traditional high pressure die casting Included alloys which may contain high amounts of silicon. With High Conductivity Casting a broad variety of alloys are available that allow us to cast with very low amounts silicon and other elements that decreases the thermal conductivity.
Designers where able to reduce the wall thickness down to 0,4 mm however with a wall height of 40 mm. This wall thickness reduction made a weight saving of 1 kg as the part went from 3.6 kg to 2.6 kg, still with a complicated geometry.
No casting is totally free of porosities but with semi solid castings the level of entrapped gas pores is so low that welding is applicable as a joining method why more advanced components can be made combining differ castings, extrusions and sheet metal parts.
High Conductivity Casting are producers of parts with high elongation, above 9% elongation. This is enabling the use of semi solid with the result of higher productivity, lower cost and complex designs. The way to make this possible is a combination of melt handling and casting parameters that has been developed with our customers.
To get a casting pressure tight is most a question of keeping a laminar flow through the whole casting cycle with a defined solidification route. Production of pressure tight castings are produced in high volumes were in line leakage tests are used to ensure delivered quality.
The technology can be used to shape complex geometries and over molding with two alloys or more. This give designers more freedom to create parts with lesser need of machining produced in a more productive process than for example gravity die casting.
Custom Heat Sinks From Forging
A good alternative to casting, forged heat sinks is an ideal solution for low to medium volume production to form complex shapes and sizes.
The production process for cold forged heat sink requires no machining, cutting, or welding, making it more cost effective than extruded or bonded-fin heat sinks. The production process lends itself very well to using copper.
A variety of heat sink fin shapes can be produced, including pin fin heat sinks, plate fin heat sinks, air foil fin heat sinks, round fin heat sinks, and square fin heat sinks. Secondary machining operations can be included in the tooling design, which decreases operational steps and waste.
Custom Specialty Heat Sinks, Passive Air Cooling Using Natural Convection
During the last ten years, developments in LED semiconductors have led to an important change in LED applications from that of luminous indicator to that of illuminator. With LEDs now advancing into several lighting fields, LEDs have become one of the standard methods of producing light, joining more traditional sources such as incandescent, fluorescent and high-intensity discharge.
Thermal dissipation is a key factor that limits the lumen output of an LED light. LED components and the driver electronics create a considerable amount of heat. If this heat is not dissipated properly, the LED’s quality of light and life expectancy decrease dramatically.
When you take into consideration the small size, high power, and cost restrictions, especially in complex environment, designs become more challenging. Spreading the heat from the LEDs, becomes very important.