If you have to get rid of a lot of heat, you need a decent heat sink, for sure. Big heat sinks are *expensive*, though, so you don't want to go making them bigger just to save a tiny dab of thermal interface material (TIM).
Cheers
Phil Hobbs
--
Dr Philip C D Hobbs
Principal Consultant
ElectroOptical Innovations LLC
Optics, Electro-optics, Photonics, Analog Electronics
160 North State Road #203
Briarcliff Manor NY 10510
hobbs at electrooptical dot net
http://electrooptical.net
The copper improves lateral heat conduction and reduces hot spots. An aluminum heat sink might be theoretically 0.1 K/W with air flow, but a transistor can see a much higher theta because it sits on a local hot spot.
--
John Larkin Highland Technology, Inc
jlarkin att highlandtechnology dott com
http://www.highlandtechnology.com
The reliability and performance of a heatsink IS theory, because you don't want to experience failures. The 'yield of the materials' is probably rather important if your heatsinking includes a nut-and-bolt connection (overtorque is a big problem, seen nearly as often as loose nuts-and-bolts floating around the box).
Really good heatsinking is mechanically demanding, and too expensive (in my experience) to be ignored in any kind of production environment. It's also a field with a plethora of snake-oil salesmen. And, those snake-oil salesmen have sold a lot of bad heatsinks to engineers.
Case in point: my stereo (Dolby 5.1, actually) was well designed EXCEPT there were heavy heatsinks depending on the solder joints of TO220 packages for support. 100 percent failure in the field.
With extruded aluminum heatsinks, lateral conduction has never been a problem. Our MEs don't have much trouble keeping the entire heatsink with 1C. Cast heatsinks aren't nearly as good, though have other properties that tend to make them the better choice.
Since the phase change temperature seems to coincide something a little worse than the worst case operating condition, it's unlikely to continue to flow.
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