Bonded fin heat sinks are generally designed for large applications that require moderate performance. Bonded fin heat sinks are made by bonding individual fins of metal to a base. The bonding can be done WITHOUT by epoxy or by brazing. The main advantage to this type of heat sink is it can be used for large applications, such as a DC-DC converter or battery charger. The main drawback is that manufacturing process labor intense resulting in a higher cost for bonded fin assembly.

 

Folded fin heat sinks are best performers if there is ducted air - flow is directed through a duct of some kind directly at the heat sink. Fin pitch can be optimized in the heat sink manufacturing process making it very high performing. Also, because the heat sink material is folded, there can be a increase in surface area over which heat can be dissipated. Fold fin heat sinks have high heat flux density. The drawbacks to this type of heat sink are the cost including manufacturing and ducting necessary in your system. In some cases, plastic can be used to create a folded fin heat sink.

 

Active Heat Sinks are those that have some kind of forced air mover on them. This might be a fan or blower, some time it is attached to the heat sink. The air movement provides air flow helping to cool down a semiconductors hot spot. Active Heat Sinks can be very efficient but not the best solution long term. Fans are made up of moving parts and can break, rendering the heat sink less than effective. These solutions cost more as well.

 

Forged Heat Sinks are done by compressing a metal, in this case aluminum or copper. Forged heat sinks may be used in a wide variety of applications. They are medium performing heat sinks that are generally inexpensive to make. Their only real limitation is they are somewhat limited in design and air flow management.

Swaged Heat Sinks are made by a swaging manufacturing process, which is a cousin to the forging process. The swaging process involves forming the metal to a die. Swaged heat sinks generally are very good performers and good for high power applications. Swaged heat sinks tend to be bulky with a limited ability to manage air flow.

Single Fin Assembly Heat Sinks are versatile for all applications. Their performance can scale from low to high performing. Some of the reasons why thermal engineers use them are because single fin assembly heat sinks are light weight and feature low profiles. They can be deployed in tight spaces. The main drawback is that they can be on the pricey side.

Skived Heat Sinks are those that are produced using the skiving process. Fins are made by making very fine cuts from block of metal, usually aluminium or copper. Skived heat sinks can be used in many applications requiring medium to high performance. The skiving process produces heat sinks with very high fin density, creating more surface area for heat dissipation. A drawback though is the thick base often seen in skived heat sinks, higher weight and the heat sinks needing to be placed properly in forced air flow to be efficient. Very much like Active Heat Sinks

Stacked Heat Sinks are made by a stacking manufacturing process, which is a cousin to the forging process. The stacked process involves forming the metal to a die. Stacked heat sinks generally are very good performers and good for high power applications. Swaged heat sinks tend to be bulky with a limited ability to manage air flow.

 

Integrated Heat Pipe Assemblies
Although heat pipes themselves do not actually dissipate significant amounts of heat, they do effectively transfer heat without a large increase in temperature. This unique transfer capability allows them to transport or spread heat to a point remote from the heat generator. A variety of basic heat sink technologies benefit from integrating heat pipes which improve conduction paths, reduce overall weight and raise thermal performance without increasing volume. The availability of a wide range of heat pipes sizes and power handling capabilities make them suitable for integration in different types of high performance heat sinks and solutions. Due to the large variety and diverse nature of customer requirements, most heat sinks using integrated heat pipes are developed specifically for the application. Heat Pipe assemblies have been used to solve thermal problems in motor drives, SMPS, transportation applications, desktop/notebook/computer servers and telecommunication.

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