65~75W Heat Sink for Down Light

Processing and Forming Technology of Radiators

Planer, cutting process

The planer type process involves first making elongated embryos with grooves through extrusion, and then using special tools to cut out layers of fins from the initial embryo. The thickness of the heat dissipation fins can be as thin as 0.5mm or less, and the fins and bottom plate are formed as a whole to avoid the hassle of interface impedance when combined with multiple materials.

The disadvantage is that during the forming process, due to the concentration of material stress, cracks may appear at the joint between the fins and the bottom plate that are not easily visible to the naked eye, which affects the heat dissipation performance of the radiator. Additionally, due to issues such as waste, mass production capacity, and defect rate, the production cost is relatively high.

Cutting technology involves cutting an entire piece of metal in one go, forming very thin and dense heat dissipation fins, effectively increasing the heat dissipation area. Due to the need for cutting, the hardness of the metal cannot be too high, so the aluminum content will be slightly higher than that of ordinary aluminum alloy heat sinks. The formed heat sink is lightweight and easy to install. Although the raw material cost of this technology is comparable to that of ordinary die-casting radiators, it has high process requirements and is difficult to process, so there are not many products available.

Precision cutting technology

Precision cutting technology refers to the process of cutting a complete profile (aluminum/copper) onto a base using a special cutting machine to create heat dissipation fins with specified spacing as needed. Compared to traditional aluminum extrusion processes, precision cutting technology can cut larger heat dissipation areas per unit volume (increasing by over 50%). The surface of the heat sink cut by precision cutting technology will form coarse particles, which can make the contact surface between the heat sink and air larger and improve heat dissipation efficiency. The biggest advantage of precision cutting is that the heat sink is integrally cut and formed, and the heat dissipation fins and base are integrated. The heat dissipation fins manufactured by precision cutting technology do not have the problem of interface thermal resistance, and the heat transfer efficiency is very high.

Extended bonding process

The expansion bonding process is somewhat similar to the gear insertion process. First, aluminum or copper plates are made into fins, and the fins are inserted into the bottom of the heat sink with grooves at high temperatures. However, during the expansion bonding process, a short copper plate is also inserted to create an interference connection and increase the connection area between the heat sink fins and the bottom of the heat sink to reduce contact thermal resistance. The contact thermal resistance of this process is very good, This process has been adopted by many Japanese manufacturers.

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