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Bonded-Fin Heat Sinks

In very demanding power applications where significant heat is generated in a small volume, Methode’s bonded-fin designs can meet your packaging needs by increasing the heat sink surface area without increasing volume, reducing thermal resistance by fifty to sixty-six percent. Bonding fins to a heat sink removes the design-limiting fin extrusion ratio found in extruded heat sinks. Typical extrusion fin ratios range from 4:1 up to a maximum 16:1; while bonded-fin designs allow ratios up to 44:1 or greater, providing cooling in forced convection for high-power applications. Fins, fabricated from sheet metal or through extrusion, are bonded to the extruded or machined base with a highly conductive thermal resin. For a complete list of Bonded Fin profiles, see the Technical Library below.

Aluminum, copper or mixed metal bonded-fin assemblies
Copper base and aluminum fin
44:1 or greater fin ratios
Fins fabricated from sheet metal or extrusion
Increased surface area
Lower thermal resistance
Up to 21 in. (533.4mm) width bases
Used for high-power forced convection applications
Highly thermal conductive bonding resin with minimal thermal loss
Fin heights based on application

Case Studies & Testimonials

High-Ratio Heat Sink Replaces Bonded-Fin SolutionMethode was approached to find a replacement for a bonded-fin heat sink that was too large, too heavy and too expensive.

Customization

Fin Length

Methode fabricates fins from sheet metal that can be sheared to specific sizes. We can customize your straight fins depending on the thermal performance requirements and package-size height constraints. For more complex designs, we can extrude fins to a specific shape and length.

Plating Options

Methode offers a variety of different plating options for all bonded fin heat sinks.

Chromate
RoHS-compliant chromate
Electroless nickel
Gold iridite
Bright chromate dip
Bright tin

Custom Designs

Methode is always developing new tooled aluminum extrusion base profiles to meet our customer's requirements. If a custom solution is required, we will support your thermal modeling and assist you to design a new profile that meets your mechanical and thermal requirements.

Technical Library

Bonded Fin Base Profiles	View	Download [PDF 272.64 KB]
Bonding Resin Properties	View	Download [PDF 242.2 KB]
Dimensional Tolerances: Extruded & Bonded Fin Heat Sinks
Design Guide: Extruded & Bonded Fin Heat Sinks	View	Download [PDF 362.58 KB]