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Folded fin heat sinks
Most of the time when we hear folding, we first think of daily things like laundry or paper. Most of us don’t consider applications that folding has in technology. Science, technology and engineering have embraced folding as a resource for innovations in a variety of fields. Material innovations that improve strength or flexibility of individual material sheets stem from the study of folding. Folding has improved storage for air bags for vehicles or solar arrays for space applications. Origami has helped develop heart stents to self-expand into place streamlining heart surgery. Folded batteries, circuits and foldable robotic forms are pushing the applications of electronics and robotics.
We can apply folding techniques in thermal management. In thermal management, folding metal sheets enables us to increase the amount of surface area within a given volume. Surface area is crucial for effective heat transfer.
Flat crest is the most common type of folded fin, since the crests or tops are where the fin stack is usually joined with a heat sink base. The flat crest fins maximize the amount of surface contact with the base, so the most heat can transfer from the base to the fins. Other types of fins are available, but their use is application specific, just like materials other than aluminum and copper. These include round crest, louvered, lanced and offset, wavy and ruffled.
Folded fins are rarely used on their own. Folded fin stacks are typically joined with a base that serves as an interface between the heat source and the fins.
The material selection determines the joining method between the fins and the base. Aluminum resists soldering, so aluminum/aluminum joints are epoxy bonded. Epoxy doesn’t adhere well to copper, so copper/copper joints tend to be soldered. If mixed between the two, typically the aluminum component is nickel plated, then the assembly is soldered together.
Folded fins are also common components in liquid cold plates and heat exchangers since they easily increase surface area and improve system and device performance. Please reach out to our team if you need help with your folded fin application.
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