Power Conversion Market – Heatsink Types & Applications
The power conversion market includes AC/DC power supplies, DC/DC converters, inverters, rectifiers, and motor drives. These systems generate high heat flux and continuous thermal loads, making effective heatsink design essential for efficiency, reliability, and long service life.
Power conversion heatsinks must manage high junction temperatures, operate reliably under continuous duty, and support compact, high-power-density designs.
Common Heatsink Types for Power Conversion Applications
1. Extruded Aluminum Heatsinks
Description:
Precision aluminum extrusions (typically 6061 or 6063) used for passive or forced-air cooling.
Key Benefits:
- Cost-effective and scalable
- Good thermal conductivity
- Easy to customize with machining and surface treatments
- Suitable for forced-air designs
Typical Applications:
- AC/DC power supplies
- DC/DC converters
- Telecom and industrial power modules
- UPS systems
2. Cold Forged Heatsinks
Description:
High-pressure forming creates dense material structures and high fin density.
Key Benefits:
- Lower thermal resistance than extrusion
- Compact footprint for high power density
- High mechanical strength
Typical Applications:
- High-density power modules
- Compact industrial power converters
- Embedded power electronics
3. Bonded Fin Heatsinks
Description:
Fins bonded or brazed to a base to maximize surface area beyond extrusion limits.
Key Benefits:
- High heat dissipation capability
- Flexible fin geometry and spacing
- Optimized for forced-air cooling
Typical Applications:
- High-power inverters
- Motor drives
- Industrial power conversion systems
4. Skived Fin Heatsinks
Description:
Fins skived directly from a solid aluminum or copper block, creating very thin, dense fins.
Key Benefits:
- Extremely high surface area
- Low thermal resistance
- Excellent performance in forced-air systems
Typical Applications:
- IGBT and MOSFET power modules
- High-frequency power converters
- Compact, high-power-density systems
5. Die Cast Aluminum Heatsinks
Description:
High-pressure die casting enables complex shapes with integrated mounting features and airflow channels.
Key Benefits:
- Structural and thermal integration
- Rugged construction
- Suitable for enclosed or harsh environments
Typical Applications:
- Vehicle-mounted power electronics
- Industrial converters
- Power control units
6. Heat Pipe & Vapor Chamber Heatsinks
Description:
Advanced heat-spreading solutions that rapidly distribute heat across the heatsink base.
Key Benefits:
- Uniform temperature distribution
- Supports high heat flux devices
- Enables compact and sealed designs
Typical Applications:
- High-power IGBT modules
- Power density–optimized converters
- Specialty power electronics
7. Liquid-Cooled Cold Plates
Description:
Liquid cold plates remove large thermal loads using circulating coolant.
Key Benefits:
- Very low thermal resistance
- Ideal for continuous high-power operation
- Stable performance under extreme loads
Typical Applications:
- High-power inverters
- EV power electronics
- Industrial and renewable energy systems
Power Conversion Applications & Thermal Requirements
| Application | Power Level | Heatsink Solution |
| AC/DC power supplies | Low–Medium | Extruded |
| DC/DC converters | Medium | Extruded / cold forged |
| Motor drives | High | Bonded fin / skived |
| Inverters (industrial/EV) | High–Very High | Bonded fin / liquid cold plate |
| UPS systems | Medium–High | Extruded / die cast |
Key Design Considerations for Power Conversion Heatsinks
- Thermal resistance (°C/W) and junction temperature limits
- Forced-air vs. liquid cooling compatibility
- Continuous-duty reliability
- Electrical isolation and creepage requirements
Mechanical robustness and vibration resistance