The advantages of liquid-cooled heat sinks are grounded in their design. Typically, heat sink plates are made of aluminum, with copper, stainless steel, or aluminum tubes in which a coolant circulates. Their compact design allows mounting directly at the hot spot, where they quickly dissipate more heat than any other cooling system. That makes them suitable as high-performance heat sinks for applications that generate intense heat. CTX Thermal Solutions shows three examples of how this principle can be customized to meet the exact requirements of the application.
For large batches: complex geometries at low costs per piece
If liquid-cooled heat sinks are needed in large quantities, CTX manufactures the heat sink plate by means of aluminum die-casting. The advantage of this process: Aluminum is cast under pressure at a defined speed into the mold, which defines the exact shape of the cooling element. This allows the simultaneous production of multiple heat sinks. The process is also suitable for the economical realization of complex geometries. The only other step is to press the tubes into the pre-formed grooves.
For high-end applications: lightweight solutions with no tool costs
For cooling in high-end applications, CTX produces liquid-cooled heat sinks by means of what is known as vacuum brazed technology. This process cross-links the molecular structures of modules. The result: heat sinks with minimal transition resistances and long-lasting bonds. For liquid-cooled heat sinks, cooling channels are milled in two plates which are then brazed together. Brazed heat sinks are up to 40 percent lighter and compacter than conventional die-cast heat sinks with the same technical properties.
For small and medium batches: high thermal conductivity and high density
Another version of liquid-cooled heat sinks has deep drawn cooling channels. They are manufactured by CTX by means of extrusion. In this process, heated aluminum or copper is pressed through the die at high pressure. This die defines the shape of the heat sink plate with its inner channels. The plates are cut from the extruded section, which has a length of six to seven meters. Then the heat sink is closed at the sides and integrated in the cooling system. This allows the production of relatively thin-walled shapes. The thermal conductivity is from 180 W/mK (aluminum cast alloy) to 400 W/mK (pure copper).
Consultation and development
CTX has the technical expertise to support customers in using the advantages of liquid-cooled heat sinks for their particular application. Based on core data such as dissipation, installation space, and production specifications, the company develops heat sinks that meet the exact requirements in terms of shape, material, and manufacturing process. The services offered range from development of new products to production according to drawings, as well as thermal simulation and implementation of logistics processes.