Methode was approached to quickly solve a preproduction thermal problem to save a customer's beta run.
Our team recommended an embedded copper heat spreader in the base of the existing heat sink, thus lowering the overall thermal resistance, limiting component temperature rise.
A leading traction drive manufacturer was suffering system failures during beta testing. The failures were caused by an inadequately sized heat sink, which was causing power electronics to overheat and fail when operated under worst-case environmental conditions. The customer needed a quick thermal fix for their existing heat sink to save their beta run, buying time to devise a more permanent fix.
We ran thermal simulations and recommended that they embed a copper heat spreader in the base of the existing heat sink, thus lowering the overall thermal resistance, limiting component temperature rise and successfully providing a quick fix to save their beta test run.
The customer confirmed that the heat spreader successfully solved the thermal problem, and later asked Methode to design an extruded heat sink to be used as a permanent fix.