I. Processing Technology
This aluminum alloy heat sink features a straight-tooth comb-like structure, requiring a balance between heat dissipation area and structural rigidity. The core process utilizes aluminum profile extrusion + finishing + surface protection treatment. The specific steps are as follows:
1. Raw Material Selection: 6063 aluminum alloy (high thermal conductivity, excellent extrusion formability, the preferred material for heat sink profiles) is selected; for high-power heat dissipation applications, 6061-T6 aluminum alloy (higher strength) can be selected, using solid aluminum rod blanks.
2. Profile Extrusion Forming:
◦ A custom comb-shaped extrusion die is used to heat the aluminum rod to 480~520℃, and then extrude it into an integrated heat sink profile through an extruder at a pressure of 80~120MPa, directly forming the heat dissipation teeth and base, ensuring consistency in tooth pitch and height.
◦ After extrusion, online quenching + artificial aging (T5 treatment) eliminates extrusion stress, prevents profile bending deformation, and simultaneously improves heat conduction efficiency and structural strength.
3. Finishing:
◦ Use a CNC saw to cut to a fixed length (tolerance ±0.2mm) to remove the extruded material ends of the profile; mill the end faces of the heat sink to ensure a good fit.
◦ If assembly positioning is required, use a CNC machining center to drill and tap the mounting holes, controlling the hole position accuracy to ≤0.1mm; slightly chamfer the edges of the heat sink teeth to avoid scratches from sharp edges.
4. Surface Treatment:
◦ Anodizing: Apply an 8~12μm thick layer of natural-colored anodizing to form a dense oxide film, improving corrosion resistance (resisting dust and moisture erosion), while the insulating properties of the oxide film prevent short circuits.
◦ Thermally Conductive Coating: Spray a nano-thermal conductive coating (thermal conductivity ≥2W/(m·K)) onto the base bonding surface to reduce the contact thermal resistance with heat-generating components.
◦ Sandblasting: Apply fine sandblasting to the surface of the heat sink to increase the heat dissipation area and create a matte finish to reduce reflection.
5. Inspection and Testing: The tooth pitch and height accuracy are measured using a 2D measuring instrument. Sampling is used for thermal imaging heat dissipation testing to verify the heat dissipation efficiency under rated power.
II. Machining Accuracy
This heat sink must ensure the regularity and installation accuracy of the heat dissipation teeth. The core indicators are as follows:
1. Dimensional Accuracy:
◦ Tooth pitch tolerance: ±0.1mm, tooth height tolerance: ±0.2mm, ensuring consistent heat dissipation area.
◦ Base thickness tolerance: ±0.1mm, overall length tolerance: ±0.2mm, adapting to installation space requirements.
◦ Mounting hole position accuracy: ≤0.1mm, hole diameter tolerance H7 grade (+0.018/0mm), ensuring precise assembly with heat-generating components.
2. Geometric Tolerances:
◦ Overall straightness of the heat sink: ≤0.2mm/100mm, preventing profile bending from affecting installation fit.
◦ Perpendicularity of heat dissipation fins to the base: ≤0.05mm, ensuring smooth airflow and reducing wind resistance.
◦ Flatness of the base mating surface: ≤0.05mm/100mm, reducing contact gaps with heat-generating components.
3. Surface Precision:
◦ Base mating surface roughness Ra0.8~1.6μm, reducing contact thermal resistance.
◦ Heat dissipation fin surface roughness Ra3.2μm, ensuring adhesion of the anodized layer.
◦ Appearance surface roughness Ra1.6~3.2μm, meeting visual and usability requirements.
III. Industry Applications
This type of aluminum alloy heat sink, with its high thermal conductivity, lightweight, and high mass production efficiency, is widely used in electronics, electrical, and communications fields. Core applications include:
1. Consumer Electronics:
◦ Computer accessories: Auxiliary heat sinks for CPUs and graphics cards; palm rest/bottom heat dissipation profiles for laptops, adapting to the thinner and lighter requirements of consumer electronics.
◦ Smart Home: Heatsinks for smart speakers and routers; lightweight aluminum alloy reduces overall device weight while ensuring adequate cooling for continuous operation.
2. Industrial Electronics:
◦ Power Supply Equipment: Heatsinks for switching power supplies and inverters; high thermal conductivity quickly dissipates heat generated during power conversion, improving equipment stability.
◦ Industrial Control Equipment: Heatsinks for PLC controllers and servo drives; suitable for high-temperature, dusty industrial environments; anodized layer enhances corrosion resistance.
3. Communication Equipment:
◦ Base Station Equipment: Heatsinks for RF modules in 5G base stations; mass-produced profiles meet the batch requirements of base station construction, while lightweight design facilitates installation.
◦ Switches/Routers: Heatsinks for enterprise-grade switches; comb-shaped serrations increase heat dissipation area, ensuring adequate cooling for 24/7 operation.
4. New Energy Sector:
◦ Photovoltaic Equipment: Heat sinks for photovoltaic inverters; the weather resistance of the aluminum alloy is suitable for the environment of outdoor photovoltaic power stations, and its high thermal conductivity improves the power generation efficiency of the inverter.
◦ Lithium Battery Equipment: Heat sinks for lithium battery protection boards; the lightweight design reduces the overall weight of the battery pack while quickly dissipating the heat generated by the cell management system.
