Thermal part:
Circuit substrate, caulking material, housing material
Heat sink part:
Shell design, surface design, surface material
Next, Xiaobian compiled the advantages and disadvantages of these materials, you are welcome to join to discuss.
Thermal part
Circuit substrate
Fiberglass board
advantage:
Low cost and easy to make
No need to consider insulation properties
Disadvantages:
Not suitable for LED design with heat sink and electrode
Need to fill the hole with tin, increase the process
Thick copper foil layer is needed to increase heat transfer efficiency
Aluminum plate
advantage:
Generally accepted
Harder than FR4, better thermal conductivity with heat sink
Electrical insulation is higher than fiberglass board
Disadvantages:
The price is higher than FR4
Less able to place other electronic components on the substrate
The thermal conductivity of the insulation layer is difficult to grasp
Copper substrate
advantage:
Thermal conductivity is much higher than aluminum substrate
Low specific heat value, easier to pull up the conduction temperature
Same advantages as aluminum substrates
Disadvantages:
High cost, general design is not applicable
Has the same disadvantages as aluminum substrates
Common gold plate
advantage:
The conduction center is unobstructed and the thermal conductivity is good.
Substrate application for high power polycrystalline LEDs
Disadvantages:
Not suitable for heat sink with electrode LED application cost is too high
Not applicable to 1~5W power applications
High mold opening cost
Composite board
advantage:
The highest thermal conductivity, up to 500W/mK
High heat rejection, no heat left on the body
Disadvantages:
Production is difficult, and the processing procedure is difficult
Poor material stability, doubts about long-term use
The cost is too high, it is difficult to commercialize mass production
Joint filler
Thermal paste
advantage:
Low cost and easy to use
No specific processing
Disadvantages:
Not easy to apply evenly, easy to form bubbles
Long-term stability of the product, easy to cure, and curing
Thermal barrier
It is easy to cause pollution to other parts during processing, increasing costs
Silicone pad
advantage:
Long temperature resistance, temperature resistance
125~200°C
The higher the temperature, the better the thermal conductivity
Flexible, not easy to form bubbles
Disadvantages:
High cost and increased product cost
Higher thickness, generally above 0.3mm
Thermal phase change silicone pad
Thermal phase change silicone pad
advantage:
Product advantage with general silicone pad
At high temperatures, the silicone will soften to increase the caulking effect.
Increase thermal conductivity
Disadvantages:
Not easy to post-process, and can not be used twice
Higher cost and increased product cost
Housing material
Aluminum-extruded (pull-up)
advantage:
High thermal conductivity and fast heat transfer
Low mold cost and length can be cut freely
Easy to process
Disadvantages:
Hardness / steel is insufficient
The appearance is relatively unchanged, and the aesthetic design is not easy
Fins dissipate heat, which is more likely to cause dust accumulation
Aluminum - die casting
advantage:
Appearance can be arbitrarily changed to beautify the appearance
Can be mass produced quickly
Disadvantages:
High mold design and development costs
Long development time, not easy to modify the design
Thermal plastic
advantage:
High insulation performance
Light weight
Easy mass production
Disadvantages:
Need to develop molding molds, high cost and long time
Poor thermal conductivity, high thermal resistance of the whole lamp system, unfavorable LED life
Plastic aluminum composite
advantage:
Can reduce the thermal resistance of the system relatively, increase the life of the LED light source, and not reduce the insulation
Disadvantages:
Complex production process, increasing production costs
Increase product weight
Heat sink
Shell design
The fin design increases the effective heat dissipation area;
Note the ratio of fin height to fin spacing;
Note the ratio of fin height to fin thickness;
Note that the width of the base and end of the fins need to be different.
Surface design
The surface can be roughened to increase the surface area;
The side fins of the columnar body can be increased to increase the effective surface area.
Surface material
Optional anodizing treatment, pay attention to its applicable temperature;
Optional high heat exchange efficiency material spraying;
Avoid mirror finishes.
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