Copper aluminium heat sink soldering
Perfectly combine the thermal spreading effect of copper with large-area aluminium cooling fins
Brazed heat sinks as a combination of copper heat spreaders or copper heat pipes with stamped aluminium cooling plates make it possible to efficiently dissipate even very high power losses from small components.
Advantages of the brazing process in heat sink production
- Standard manufacturing process
- Customised solutions
- Copper-aluminium combination possible
- Contact resistances are reduced to a minimum
- Very many thin cooling fins/cooling fins possible
- Production of high-performance heat sinks that are significantly lighter and more compact than standard aluminium heat sinks with the same cooling capacity
- Various surface finishes possible
(nickel plating, cathodic dip painting/lacquering)
The soldered connection between copper heat spreader and copper heat sink, but also between copper/aluminium combinations, provides a durable and reliable mechanical connection. The soldered connection also ensures ideal heat transfer between the two materials, which remains stable even with temperature fluctuations.
Increased performance of brazed heat sinks through a combination of different techniques
Heat sinks with brazed-on cooling fins enable improved heat transfer while at the same time offering a high degree of flexibility in the design of the entire heat sink. In combination with other cooling technologies, such as heat pipes or active ventilation systems, these heat sinks can significantly increase the overall cooling performance by enabling fast and effective heat dissipation.
Brazed heat sink+ copper plate
The excellent heat spread of the copper plate quickly distributes the heat to the cooling fins, resulting in more even and effective cooling. In addition, the copper plate acts as a buffer during heat peaks by absorbing excess heat and releasing it slowly, reducing the risk of overheating.
Brazed heat sink+ heatpipes
Heat pipes distribute the heat quickly over a large surface area. This even heat distribution avoids hotspots and enables rapid heat dissipation. The flexibility in the utilisation of installation space allows heat to be transported over longer distances, which is particularly advantageous in complex systems. This technology also enables weight savings with the same or even improved performance.
Brazed heat sink+ vapour chamber
The excellent heat spread of the vapour chamber ensures efficient heat dissipation over the entire surface of the heat sink. This technology also works excellently in conjunction with heat pipes to achieve even better heat transfer. Compared to a full copper plate, a vapour chamber saves a lot of weight, which is particularly important in mobile applications. In addition, the even heat distribution prevents hotspots and ensures a low temperature gradient.
Let's talk about your cooling task!
Danny Weimer
Sales Department
+49 (0)7561 9837-28
d.weimer@ekl-ag.de
Make an appointment Enquiries by e-mail
Danny Weimer
Sales Department
+49 (0)7561 9837-28
d.weimer@ekl-ag.de
Make an appointment Enquiries by e-mail
Soldering in the manufacturing process
In addition to selecting the ideal solder (lead-free and RoHS-compliant, of course), the appropriate soldering process and the perfect setting parameters for temperature and time, a well thought-out and solid soldering device is also required to achieve an perfect connection. Thanks to decades of experience and millions of heat sinks produced, we guarantee a very high level of process reliability.
Efficiency and economy combined for maximised cooling performance
Copper has a high thermal conductivity, which makes it an excellent material for heat transfer. Aluminium is known for its lightness and cost efficiency. Brazed heat sinks with this combination of materials are often used in high-performance computer systems to reliably regulate the temperature of CPUs and GPUs in servers and gaming PCs. They are also advantageous in power electronics, for example in frequency converters and power modules, due to their ability to dissipate high temperatures quickly. In industrial applications, they are used to cool critical components such as drives and control units. They ensure reliable performance under varying operating conditions and even under strong vibrations.
The heat sink combination of copper and aluminium offers a good balance between efficiency and economy, making it a preferred choice for many applications where effective heat dissipation of high power dissipation is required.
The heat sink combination of copper and aluminium offers a good balance between efficiency and economy, making it a preferred choice for many applications where effective heat dissipation of high power dissipation is required.
Added value and extras
Our full service goes beyond the mere development, series production and logistics of your heat sinks. Do you need special bores or milling on your heat sinks? Do you want your heat sink to not only dissipate a lot of heat, but also look stylish? Would you like a product ready-to-plug-in with all accessories?
Welcome to EKL!
Welcome to EKL!
CNC machining
For prototypes, small series and customised reworking of heat sinks, we have modern 3- and 5-axis CNC milling machinesat our company headquarters. Complex machined and high-precision radiators are our speciality. Working areas of the machines:
Hermle C 400 (5-axis) 850 x 700 x 500 mm | Mikron VCE1000pro (3-axis) 1000 x 560 x 600 mm | Kondia B1050 (3-axis): 1000 x 500 x 600 mm
Hermle C 400 (5-axis) 850 x 700 x 500 mm | Mikron VCE1000pro (3-axis) 1000 x 560 x 600 mm | Kondia B1050 (3-axis): 1000 x 500 x 600 mm
Surface finishing
Our range includes various surface finishes to create a durable, corrosion-resistant surface. Nickel plating increases wear resistance and lustre. Chromating and passivation, especially with Surtec 650, provide additional protection against corrosion. Powder coating is another option for a robust and durable coloured surface. Painting and cathodic dip coating round off our wide range of surface colours and textures.
Attachments & accessories
Depending on the application, screws, springs or push pins ensure the secure and stable attachment of the heat sinks. Backplates provide additional stability and improved heat dissipation. Heat-conducting pastes and pads are naturally part of our range to enable optimum heat transfer between the heat sink and the heat source.
Secure packaging for transport
With a focus on perfect protection during transport, we develop packaging that not only fits perfectly but is also robust. Another important aspect of the range is the use of recyclable materials that contribute to sustainability and environmental friendliness.
Soldered heatsinks in typical areas of application
Aluminium-copper heat sinks offer high thermal conductivity at a favourable price-performance ratio. Aluminium dissipates heat efficiently and is lightweight, while copper has even better heat dissipation properties. For some applications, copper heat spreaders with soldered copper cooling fins are the better, yet more expensive, alternative. Soldering the metals creates a material bond that enables ideal heat transfer. The soldering process also enables a durable and robust connection that allows the heat sinks to function reliably even in demanding applications.
- 30 years of experience
- Engineering in Germany
- Full Service Heat Sink
- Cost-efficient development
- Fast market launch
- Maximum quality
The EKL project stages for your cooling solutionChoose your point of entry!
Our offer is as flexible as your needs. Are you still early in the development phase and want an idea generator for the best cooling solution? Do you have a ready-made device that gets too hot? Or are you simply looking for an alternative or additional supplier for a heat sink already used in series production? In EKL you will always find a flexible, agile and responsible partner for the cooling of your electronic components and complete systems, whatever the project phase. We look forward to your enquiry!
Counselling
Concept
Concept
In personal contact and open dialogue with you, our engineers create the creative space and framework to design the best cooling solution for your requirements from the wealth of options available.
Development
Feasibility / simulation
Feasibility / simulation
We test the idea for your heat sink virtually in the thermal simulation. Realistic computer simulations allow variations in manufacturing processes, system structures and other parameters.
Performance optimisation
Even a well-functioning heat sink can still be optimised. We determine the "how" and "how much" by simulating different materials or cooling technologies, for example, as well as simulating various environmental parameters.
Cost optimisation
An expensive heat sink can often be made significantly cheaper by using an alternative manufacturing process. Whether with the same or application-specific performance: we support your product development in reducing costs.
Production drawing
Prototype construction
Prototype construction
Prototypes from our design department enable early testing and targeted solutions to problems in your device. We create your functional and design prototypes with our in-house CNC production.
Series production
small to large
small to large
By manufacturing in-house and in Asia, we can offer all types of heat sinks from small to large series at competitive unit prices. We impress our long-standing customers with our consistently high quality.
Sampling
Incoming goods inspection
Incoming goods inspection
We make no compromises when it comes to quality: Development takes place in Germany and all series products are analysed by our German test laboratory according to test plans using state-of-the-art methods.
Surface finishing
Anodising, powder coating, painting etc. protect your heat sinks from corrosion and environmental influences. But colour is not just chic, because dark-coloured heat sinks also emit more radiant heat.
Assemblies
Pre-assembly
Pre-assembly
We actively relieve your production with pre-assembled assemblies. This reduces your workload per device and guarantees the highest quality, because as cooling professionals we ensure that the heat sink is optimally attached.
Quality assurance
Test plans
Test plans
We test according to our own and customer-specific test plans using the latest rapid thermal measuring equipment, 3D measuring machines, assembly tests and testing of various application scenarios.
Packaging design
Packaging production
Packaging production
EKL develops and produces customised packaging to optimally protect your sensitive heat sinks or assemblies in the sometimes harsh transport and storage environments.
Warehouse
& Logistics
& Logistics
With large storage capacities, we offer production-related stocking and consignment warehouses, just-in-time deliveries, customised delivery schedules and flexible shipping options for your individual requirements.
Brazed Fin manufacturing process in direct comparison
A filter is active, some data is hidden
| Extruded heat sinks | Cold forged heat sinks | Soldered heat sinks | Bonded cooling fins | Pressed cooling fins | Friction stir welding | Heatpipes | Vapour Chamber | Crimped heat sinks | Skived Fins | Die casting | Laserwelding | Vacuum brazing | |
|---|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Thermal conductivity | |||||||||||||
| Heat dissipation over long distances | |||||||||||||
| Design freedom and flexibility in shape and size | |||||||||||||
| Low tool costs / initial investment | |||||||||||||
| Favourable unit prices | |||||||||||||
| Low set-up costs | |||||||||||||
| Economic efficiency for small series | |||||||||||||
| Economic efficiency for large series | |||||||||||||
| Can be combined with other technologies | |||||||||||||
| Surface finishing / resistance | |||||||||||||
| Heat transfer | |||||||||||||
| Standard products | |||||||||||||
| Material density | n.a. | n.a. | n.a. | n.a. | n.a. | n.a. | |||||||
| Space-saving, large surface area in a small space | |||||||||||||
| Weight-saving | |||||||||||||
| Position dependence / gravity dependence | |||||||||||||
| Machinability | |||||||||||||
| Mechanical stability | |||||||||||||
| Low wear and tear | |||||||||||||
| Homogeneity (material, no additional materials) | |||||||||||||
| Suitability for large coolers | |||||||||||||
| Suitability for small coolers |
• less suitable | ••••• excellently suited | n.a.: not applicable
Let's talk about your cooling task!
Frank Sichler
Sales Manager
+49 (0)7561 9837-47
f.sichler@ekl-ag.de
Make an appointment Enquiries by e-mail
Frank Sichler
Sales Manager
+49 (0)7561 9837-47
f.sichler@ekl-ag.de
Make an appointment Enquiries by e-mail