LED Heat Sinks
LED heat dissipation profiles mainly refer to aluminum extruded profiles used for heat dissipation in LED lighting casings or internal heater accessories or other LED products. LED heat sink profiles can be customized with non-standard molds based on incoming drawings or samples. For production, mold opening and custom extrusion are carried out according to actual usage scenarios or needs, to create a variety of shapes and meet different assembly or actual usage requirements.
Let's check the Common Processes for LED Lamp Heat Sinks
Die casting LED Heat Sinks
Die castings are parts produced through a pressure casting process. Using a die-casting machine equipped with a mold, metals such as copper, zinc, aluminum, or aluminum alloys, heated to a liquid state, are poured into the feeding port of the die-casting machine. Through the pressure applied by the machine, these metals are cast into parts with shapes and dimensions restricted by the mold. Such parts are commonly referred to as die castings.
Features of Die Castings LED Heat Sinks:
1.Complex Shapes: Die castings can be made into many complex shapes with high precision and smooth finishes.
2.Surface Imperfections: The surface of die castings may have flow marks, so they often require polishing treatment.
3.High Mold Cost: The cost of die-casting molds is relatively high, and the heat dissipation is poorer compared to other processes.
4.High Production Efficiency: Die casting offers high production efficiency.
Aluminum Extrusions LED Heat Sinks
Aluminum extrusion is the process of shaping liquefied metal through a fixed mold and then cutting it into various shapes. Common materials used for aluminum extrusion molds include AL6063 and AL6061.
Features of Aluminum Extrusions LED Heat Sinks:
1. Low Mold Cost: The cost of molds is relatively low.
2. High Post-Processing Cost: The cost of post-processing is relatively high.
3. Simple Forming: The forming process is relatively simple. The shapes of aluminum extrusion molds are quite uniform, and many features are mainly achieved through post-processing.
Stamped LED heat sinks
Stamped parts are produced through a forming process that applies external force to sheet metal, strip, tubing, and profiles using a press and mold. This causes plastic deformation or separation to achieve the desired shape and dimensions. Stamped parts are formed by applying external force through a press and mold to sheet metal, strip, tubing, and profiles, causing plastic deformation or separation to obtain the required shape and size. Stamping and forging both belong to plastic processing (or pressure processing) and are collectively referred to as forging and pressing. The primary raw materials for stamping are hot-rolled and cold-rolled steel sheets and strips. Common aluminum alloys used for stamping include 6063, 5052, and 6061.
Features of Stamped LED Heat Sinks:
1.Lightweight: Stamped parts are very light.
2.High Material Utilization: The material utilization rate is high.
3.High Production Efficiency: The production efficiency is high.
4.Short Mold Lifespan: The lifespan of the molds is generally short.
Finned LED Heat Sinks
A type of heat dissipation fin includes a main body and two connecting sections. Each end of the main body has two fixed holes, with a perforation in the middle. At the perforation, a coupling section protrudes to one side of the heat dissipation fin, allowing the fin to engage with a heat pipe through the perforation and connecting sections. The connecting section extends perpendicularly outward from each end of the main body and includes a vertical section and a bearing section.
The vertical section comprises one first accommodating block and two second accommodating blocks. Each side of the first accommodating block forms a first accommodating section, while a second accommodating section is formed between the two second accommodating blocks. The bearing section extends perpendicularly inward from the second accommodating section of the vertical section, parallel to the main body. Additionally, two fixed protrusions are positioned on the bearing section, corresponding to the fixed holes in the main body.
Advantages of Finned type LED Heat Sinks
1. Lighter construction
2. Increased heat dissipation surface area
3. Improved thermal performance
For instance, high-altitude industrial and mining lamps made from traditional die-cast aluminum and extruded aluminum are heavier and pose certain safety risks. Fin-type heat sinks are safer in these applications.
Aluminum extrusion
Advantages: The heatsinks produced by this process have excellent heat dissipation performance and require almost no maintenance.
Disadvantages: The cost of aluminum extrusion is high and may not be suitable for large-scale applications.
Copper purification
Advantages: The copper purification process can produce heatsinks with excellent heat dissipation performance.
Disadvantages: The manufacturing cost is high and requires regular cleaning and maintenance.
Aluminum oxidation
Advantages: The heatsinks produced by aluminum oxidation have excellent heat dissipation and corrosion resistance.
Disadvantages: The manufacturing cost is high and requires regular cleaning and maintenance.
Cooling pool
Advantages: The cooling pool process can produce heatsinks with good heat dissipation and low cost.
Disadvantages: Regular cleaning and maintenance are required using cleaning agents.
Heat pipe technology
Advantages: The heatsinks produced by heat pipe technology have excellent heat dissipation performance and relatively low cost.
Disadvantages: Regular cleaning and maintenance are required, and repairs can be difficult if there are problems.
Among them, aluminum extrusion and aluminum oxidation are the two most widely used manufacturing processes because they not only have good heat dissipation performance but also have high stability and can operate for a long time.
Shanghai Jwell machinery Workshop co-operation projects
AAE B.V.--Netherland
Automotive Electronics
Project Difficulty
High gear density
High tolerance requirements
High flatness requirements
Extremely high extrusion production
What problem did we solve for customer?
ZP helped to improve the heat dissipation performance of products and meet customer tolerance requirements, and successfully meet the standards of application and mass production, which finally realize mass production of the products designed by customer.
iWave--India
Automotive, Medical
Project Difficulty
High gear height, high extrusion difficulty
High surface treatment standard: nearly no defect
Assembly with specified accessories.
What problem did we solve for customer?
According to the high surface requirements of customers, after a year of continuous proofing and testing of different accessories, the product can be successfully mass produced.
STAGE ONE--Taiwan, China
Stage Lighting Heat Sink
Project Difficulty
Large stage lamp heatsink, wide, unsupported cavity. High requirements for surface treatment: The surface requires liquid baking paint (spray paint) which the cost is higher than other surface treatment.
What problem did we solve for customer?
The mold was continuously optimized to solve the problem of cavity depression and bone shadow on both sides during extrusion.
ZP HEAT SINK has been engaged in aluminum profile customization in Foshan for 20 years, serving 6,000+ large and small customers, and cooperating with 10,000+ sets of molds. It has rich experience in customized development and production. If you need an aluminum profile manufacturer with good service and sufficient experience, or for aluminum If you have any questions about alloy profiles, you can directly consult our online engineers.
We're well-known as one of the leading led heat sinks manufacturers and suppliers in China. If you're going to buy or wholesale high quality led heat sinks with competitive price, welcome to get free sample from our factory. Also, customized service is available.
LED bulb cooler, extruded LED heatsinks, high power LED heatsink(0/10)
