Thermal - Heat Sinks

Part Number	Description / PDF	Quantity
507222B00000G Aavid	HEATSINK TO-220 DUAL 10W	2163
320105B00000G Aavid	TO-5 PUSH-ON HEATSINK 6.35MM	0
581102B00000 Aavid	HEATSINK TO-220 2.5W H=1.5" BLK	0
577500B00000G Aavid	HEATSINK TO-126 VERT MNT SLIP-ON	1989
532702B02500G Aavid	HEATSINK TO-220 SOLDERPIN 50.8MM	0
590302B03600G Aavid	HEATSINK TO-220 CLIP-ON BLACK	557
7141DG Aavid	BOARD LEVEL HEATSINK .515"TO-220	6300
780752F00000G Aavid	78075 EXTRUSION 2.13X1.5"X4.1'	14
7023B-MTG Aavid	BOARD LEVEL HEATSINK 1.95" TO220	0
530102B00150G Aavid	HEAT SINK 1.75" HIGH RISE TO-220	0
501603B00000G Aavid	HEAT SINK TO-3 1.25" COMPACT	70
7024B-MTG Aavid	HEATSINK TO-220 TAB FOLD 41.15MM	0
374324B60023G Aavid	BGA HEAT SINK	0
HF35G Aavid	HEATSINK TO-220 TAB/CLIP-ON	788
374724B00035G Aavid	HEATSINK BGA 35X35X18MM W/ADH	648
581102B02500G Aavid	HEATSINK TO-220 2.5W BLK W/PINS	2420
342940 Aavid	COPPER HEATSINK 38.5X37.6X14MM	0
HF20G Aavid	HEATSINK TO-220 TAB/CLIP-ON	0
725452F00000 Aavid	62545 EXTRUSION 2.75X14.75"X4'	0
6021BG Aavid	HEATSINK TO-220 TABS BLACK	1971

Thermal - Heat Sinks

1. Overview

Thermal heat sinks are passive or active cooling components designed to absorb and dissipate heat generated by electronic devices. They play a critical role in maintaining optimal operating temperatures for semiconductors, processors, and power modules. As modern electronics trend toward higher power density and miniaturization, effective thermal management through heat sinks has become essential for ensuring reliability, performance, and longevity of systems in applications ranging from consumer electronics to industrial machinery.

2. Main Types and Functional Classification

Type	Functional Features	Application Examples
Passive Air-Cooled Heat Sinks	Aluminum/copper fins without moving parts	Desktop CPUs, LED lighting
Active Air-Cooled Heat Sinks	Fans integrated with fin arrays	Gaming PCs, industrial control cabinets
Liquid-Cooled Heat Sinks	Internal channels for coolant circulation	Data center servers, EV battery packs
Heat Pipe Heat Sinks	Vapor chamber technology for ultra-thin profiles	Smartphones, aerospace electronics
Phase Change Heat Sinks	Paraffin-based materials absorbing latent heat	Short-duration high-load applications

3. Structure and Components

Typical heat sink structures include:

Finned Arrays: Corrugated metal surfaces (aluminum extrusions or folded copper sheets) for maximizing surface area
Base Plates: Machined or forged bases with micro-channel patterns for direct component contact
Thermal Interface Materials (TIMs): Graphite pads or phase-change materials between heat sink and component
Mounting Hardware: Spring-loaded pins or adhesive backers for secure installation
Protective Coatings: Anodized finishes or nickel plating for corrosion resistance

4. Key Technical Specifications

Parameter	Description	Importance
Thermal Resistance	0.5-10 C/W range depending on design	Directly impacts cooling efficiency
Material Conductivity	Al: 180-240 W/m K \| Cu: 390-400 W/m K	Determines heat transfer speed
Fin Density	5-50 fins per inch (FPI)	Affects airflow resistance and surface area
Operating Temperature	-50 C to +250 C typical range	Defines environmental suitability
Weight	50g-10kg depending on application	Critical for aerospace and mobile uses

5. Application Fields

Consumer Electronics: CPU/GPU cooling in computers, smartphone SoC thermal pads
Telecommunications: 5G base station power amplifiers, optical transceivers
Industrial: VFD motor controllers, welding equipment
Automotive: Electric vehicle (EV) battery packs, onboard chargers
Aerospace: Avionics cooling systems, satellite power modules

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
Aavid (TE Connectivity)	HiK Plate Heat Sinks	Embedded heat pipes, thermal conductivity >400 W/m K
Cooler Master	Hyper 212 RGB	4 direct-contact heat pipes, 64 CFM fan
Delta Electronics	CD7010 Liquid Cooler	2-phase immersion cooling system
Thermaltake	Floe Riing RGB 360mm	360mm radiator with RGB lighting
Boyd Corporation	Phase Change PCM150	150W thermal capacity for pulsed loads

7. Selection Guidelines

Key considerations include:

Calculate required thermal dissipation using Q = (T_operating - T_ambient)/R_thermal
Verify dimensional compatibility with component footprint and clearance
Assess environmental conditions (humidity, vibration, corrosion potential)
Balance performance vs cost: Extruded aluminum offers best cost/performance ratio
Consider integration with existing cooling systems (e.g., existing fan airflow rates)

Case Study: For a 150W CPU with 70 C max operating temperature and 25 C ambient, required thermal resistance must be 0.3 C/W. Recommended solution: Copper base heat sink with 6 heat pipes and 120mm PWM fan.

8. Industry Trends

Emerging developments include:

Graphene-enhanced composites achieving 500+ W/m K conductivity
3D-printed lattice structures reducing weight by 40% while maintaining performance
Smart heat sinks with embedded thermal sensors and adaptive fan control
Two-phase immersion cooling systems for data centers (up to 90% energy savings)
Microchannel liquid cooling for 5G millimeter-wave transmitters

Market forecasts predict a CAGR of 6.8% through 2030, driven by EV and 5G infrastructure demands.