Category Archives: Heat Sinks

ATS thermal consulting team gives leading LED manufacturer a 33% improvement in their heatsinkperformance

A leading LED manufacturer approached ATS regarding a high heat LED thermal management problem. Their original heat sink design for a 6W LED light with a vertical orientation had specifications of Rhs of 9 K/W and a dThs of 54 C at ambient.

ATS analyzed their design, factoring in the position of the light (vertical) and how they might effect the design to bring greater improvements and headroom. ATS’s thermal engineering consulting included:

  • Testing the heat sink physically in our thermal lab
  • Creating models using CFD to determine the optimal design
  • Developing and Manufacturing samples to be re-tested in our lab, prior to moving to general availability for our customer.

The result was a 33% improvement in the heatsinks performance. See the following chart for the before and after technical results (click chart for a clearer and larger image):

LED Thermal Design Case Study Chart

 

ATS can supply consulting services to do the same for your LED heat sink design. For more information on our LED design consulting services, visit ATS at our LED Consulting Page.

ATS releases test data on thermal resistance of its heatsink for LGA Socket

We do alot of testing of our heatsinks here at Advanced Thermal Solutions. Our labs are regularly hot with test activity since we prefer to publish accurate test data on our product’s performance. Our LGA heatsink is one in particular.

Our ATS-57000 LGA Heatsink was put through it’s paces and we have some impressive test data.

Scenario: The required thermal target performance was 0.7°C/W with a 60W heat load and 12.4×15.3mm die size. The thermal solution was verified by 3 independent methods; analytical modeling, CFD simulations, and laboratory testing.

What did we do: First, an analytical approach was used to provide a first order calculation of thermal performance. From these calculations we found that a 40 millimeter fan would provide sufficient airflow to meet the cooling objective. These calculations provided a foundation on which to base our solid models on. After modeling the heatsink and fan, the assembly was simulated in CFDesign, a computational fluid dynamics software tool.

Once the optimal heatsink geometry was found in CFD simulation, a prototype was machined and tested in the ATS Fluids Laboratory. The testing involved several different interface materials from grease through phase change material.

What were the results?: During laboratory testing the heatsink thermal resistance was 0.51 to 0.58°C/W with various types of thermal grease. This performance level exceeds the given specification of 0.7°C/W with an 18% margin of safety. A further improvement of approximately 4% can be reached with a higher output AVC fan

Readers of our blog are welcome to email us for the full report. Also, our design is highly scalable to a custom version as well. Because we have an exisiting design your custom costs will be lower than anyone starting from scratch. Drop me some mail at [email protected] for your free copy of our report.

LED Heatsink from ATS Designed Specifically to Cool Higher Power, Surface Mount LED Lighting

LED Heat Sinks

ATS Star LED heat sinks provide thermal management for high-powered LED systems. (Advanced Thermal Solutions, Inc.)

Advanced Thermal Solutions, Inc. (ATS) offers their LED heat sink family, the Star Series of heat sinks, designed specifically for the thermal management of higher power, surface mount power LED lighting. High temperatures not only degrade an LED’s lifetime, but also result in lower light or non-uniform output effects that can significantly affect their application. The 32 new Star heat sinks provide enhanced conductive heat transfer for effective LED cooling without fans or blowers. Cooling performance in the series reaches more than 60 K at up to 16 Watts of power dissipation.

All Star heat sinks are aluminum heat sinks in a cylindrical shape that fits common LED lamp applications. Their cooling fins are arrayed in a round, star-like cross section that optimizes thermal performance through radiative cooling to the local air flow. A flat surface at one end of the heat sink provides a base for direct mounting of LEDs.

Integral threads on the base perimeter allow attachment of brackets and other hardware. All standard sizes are available with an inner thread for convenient attachment of LED lens mounts. ATS Star heat sinks are available in 25, 45, 50 and 75 mm (0.98, 1.77, 1.96 and 2.95 inches) lengths with a standard diameter of 45 mm (1.77 inches).

Each heat sink features a black anodized finish that provides corrosion resistance, electrical insulation, and improved thermal management performance. All heat sinks within the series are RoHS compliant. Unit pricing for Star Series LED cooling solutions start at less than $8.00 in production quantities.

Visit STAR LED Heat Sinks Page to see the entire family or for more information email ATS sales at [email protected] or call 1-781-769-2800.

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Thermal Management in Medical Diagnostic Equipment : ATS Thermal Webinar, June 11, 2PM

Thermal challenges in medical diagnostic equipment such as EKG machines, defibrillators, telemetry, ultrasound and other products present both similar challenges to other electronics as well as their unique set of needs due to their importance in people’s lives. This free vertical webinar will focus on the specific needs that medical diagnostic equipment requires.

To register for this free webinar, please click to: Thermal Management in Medical Diagnostic Equipment, June 11 2PM

Thermal Management of Medical Equipment is not just about keeping it cool; it might mean life or death for the patient

Yesterday we noted Thermacore’s new white paper, “Thermal Management for Today’s Medical Devices and Equipment“. As we noted yesterday, we couldn’t agree more with Thermacore’s premise. Here at ATS, our team thinks the topic of proper thermal management of medical equipment is vitally important to people’s lives. So important, we wanted to post a bit more about it.

Key trends we are seeing in thermal development in the medical industry:

  • Unquestioned Reliability
  • Instruments with greater accuracy and capability
  • Reduced size and miniaturization

Reliability is important on at least two levels. First, if the equipment is not reliable, the economic payback simply won’t be there for a physician, clinic or hospital. For example, CT scanner’s can cost up to $300,000. If it’s unreliable due to thermal stress, the payback investment might be twice as long as what would generally be seen.

The second reason for reliability is for patient and doctor confidence. Patients want to have confidence in the equipment they are being tested on. This can reduce their personal stress by trusting the results they will receive are accurate. Doctor’s want to be confident in the diagnostic equipment they are using. Doctor’s want to trust the data they get is accurate enough for them to determine a diagnosis.

The accuracy and diagnostic capability is important too. For any medical equipment to be useful the data collected has to be accurate or else a wrong diagnosis might occur.
The fallout from that reduced accuracy can be devastating as incorrect diagnosis may be formed leading to an incorrect course of healing for the patient. Poor thermal management of key components and entire systems can cause processors within the medical equpiment to overheat, slowdown and potentially return data errors.

Finally, reduced size and miniaturization can mean diagnostic equipment gets deployed more widely increasing it’s potential use and benefitting the health of the population where it is used. The packaging for this smaller equipment requires careful attention to the thermal design. Regardless of how low power the components used, the smaller the space, the more the airflow will be reduced and the increased likelihood for thermal stress and component malfunction.

Thermal management of electronics is critical to their functioning properly and being a tool that helps people’s health. At ATS, we have developed thermal management solutions, including heat sinks, for a variety of medical applications from EKG machines, to Defibrillators, to Ultrasound equipment and Tissue/DNA Analyzation instruments. To learn more about our thermal management consulting for medical equipment, please visit our web site at this link: ATS Thermal Management of Medical Applications. You can also drop us a line to tell us about your application and how we might help by clicking to our on-line engineering services request at our web site: Analysis and Design Services Request