Bonded Fin Cold Plates Custom

Winshare Thermal Alloy: Provides efficient and reliable liquid cooling solutions for high heat flux density applications.

What Is Bonded/Brazed Fin Cold Plate?

Bonded/brazed fin cold plates are advanced liquid-cooled radiators designed to solve the problem of high power, high heat flux density heat dissipation. It is unique in that it uses a pre-stamped, high-density fin array to be positioned through a runner groove on a precision-machined base plate, and advanced bonding or vacuum brazing technology to securely bond the fins to the base plate.

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This structure uses fins to create a large internal heat transfer surface area within the runner, which is 3 to 5 times larger than that of a conventional drilled cold plate. When coolant flows through these dense fins, it produces a significant turbulence effect, effectively breaking the boundary layer and greatly improving the heat transfer coefficient. Finally, the entire structure is encapsulated by a sealed cover to ensure that the runner is intact and leak-free.

Core processes and advantages:

Brazing: In a high-temperature vacuum environment, the metallurgical bonding of the fins and the base plate is achieved by filling the brazing material, with high connection strength and extremely low thermal resistance. Epoxy Bonding: Bonding with epoxy resin with high thermal conductivity is a simple process and low cost, suitable for applications with relatively loose thermal resistance requirements. Structural advantages: The combination of fins and bottom plates realizes the perfect integration of fluid convection heat transfer and solid conduction heat transfer, and the heat dissipation performance far exceeds that of a single process cold plate.

The Core Benefits of Winshare Bonded Fin Cold Plates

The manufacture of precision-drilled cold plates places high demands on material uniformity and machinability. Winshare Thermal Alloy is capable of performing precision deep hole drilling on a variety of high-performance metals to meet the most demanding heat dissipation requirements:

Superior heat dissipation and high heat flux density support

Through precision-engineered fin geometries and high-density runners, our cold plates provide a large internal heat transfer surface area and significantly increase the heat transfer coefficient. This enables our products to effectively handle high heat loads up to 1500W and above, as well as high heat flux density challenges of more than 200W per square centimeter.

Excellent cost-effectiveness and mass production advantages

Compared to processes such as deep hole drilling or friction stir welding (FSW), bonded fin cold plates have a more mature and cost-controlled production process. It offers near-top performance while effectively reducing overall manufacturing costs, making it ideal for medium to high-volume production needs, offering the perfect combination of performance and affordability.

Highly flexible and customized design

Our team of engineers can flexibly customize the type of fins (e.g., straight, folded, or staggered), the height and spacing of the fins, and the runner layout according to your specific needs. This allows the cold plate to perfectly match different heat source shapes, power distributions, and system flow resistance requirements.

Superior structural reliability and durability

Our vacuum brazing process creates a strong metallurgical bond that ensures a strong connection between the fins and the base plate with very low thermal resistance. With strict testing processes, the product has excellent vibration resistance and high pressure resistance, providing long-term stable reliability guarantee.

Support large size and special-shaped customization

Unlike extruded cold plates with limited mold size, the bonding cold plate process can easily manufacture larger cold plates to meet the heat dissipation needs of large heat sources (such as server blades, high-power IGBT modules), providing great design freedom.

Diverse material combinations and surface treatments

We can combine different materials according to specific application needs, such as copper fins with better thermal conductivity and lightweight aluminum baseplates. At the same time, various surface treatments such as nickel plating and anodizing are available to enhance corrosion resistance.

Why Choose Winshare Thermal Alloy?

Professional thermal design and CFD simulation team

We have a team of thermal management engineers with over a decade of experience in CFD simulation and thermal design optimization. We can intervene deeply from the early stages of your project to provide you with the most accurate and efficient cooling solutions.

Advanced manufacturing process and equipment

We are equipped with leading CNC machining centers, high-precision vacuum brazing furnaces, and professional bonding equipment to ensure the manufacturing accuracy and process quality of each cold plate. We adhere to industry-leading production standards.

Strict quality control system
We strictly follow ISO 9001 and IATF 16949 and other quality standards, and establish a quality control system from raw materials to finished products to ensure high reliability of products, especially to meet the needs of demanding fields such as automotive electronics.

Quick response and customer support
Our sales and technical support teams can quickly respond to your inquiries and technical questions, providing comprehensive and efficient support from design consultation and sample manufacturing to mass production and after-sales service.

Bonded Fin Cold Plates Core Product Parameters and Customization Capabilities

Winshare's bonded fin cold plates offer a fully customized service. Below is the scope of our design capabilities, which we will precisely optimize to meet your specific application needs.

Thermal Resistance

Achieves as low as 0.015 °C/W
The lower the temperature rise generated by the heat source per watt of power, the better the heat dissipation performance.

Runner design

Fin densities can reach 30 fins/inch

Customize multiple fin types (straight, folded, staggered) and runner layouts to balance cooling performance with system pressure drop.

Dimension

Up to 1500mm × 800mm

It breaks through the size limitations of the extrusion process, especially suitable for large heat sources such as large server blades and battery packs.

Operating Pressure

Up to 200 PSI
Through advanced vacuum brazing processes and rigorous high-pressure testing, the structural integrity and tightness of cold plates under harsh working conditions are ensured.

Surface Flatness

Better than 0.05 mm
Through precision CNC machining and fine grinding processes, it ensures that the cold plate maximizes contact with the heat source surface and minimizes contact thermal resistance.

Fluid Connectors

Multiple interface options

Multiple interface customizations are supported, such as NPT, BSPP threaded fittings, quick couplings, etc., to be compatible with your existing system.

Bonded Fin Cold Plates Commonly Used Core Materials

Aluminum alloy

Commonly used grades: 6061, 6063 Advantages: Lightweight, cost-effective, easy to process. It is the material of choice for most liquid cooling applications, providing excellent heat dissipation and good corrosion resistance.

Copper alloy

Commonly used grade: C11000 (pure copper) Advantages: Thermal conductivity of up to 400 W/m·K, twice that of aluminum. It is suitable for ultra-high heat flux density applications where extreme thermal performance is required.

Mixed materials

We can combine different materials, such as: - Copper Base Plate + Aluminum Fins: Utilizes the ultra-high thermal conductivity of copper to contact the heat source, while taking advantage of the lightweight and cost advantages of aluminum as a fin material.

Winshare Quality Certification and Assurance

We understand that the reliability of our products is crucial. Winshare has established a comprehensive quality management system and conducts multiple rigorous tests on each product to ensure its performance and long-term stability.

Our main certifications:

ISO 9001:2015: Internationally recognized quality management system certification, covering the entire product life cycle.
   IATF 16949: Quality Management System for the Automotive Industry to provide the highest assurance for automotive electronics customers.
   ISO 14001:2015: Environmental Management System certification, reflecting our commitment to environmental protection.
   UL / CE / RoHS: Products comply with safety and environmental regulations in major markets around the world.
Rigorous factory testing

Helium Mass Spectrometry Leak Detection Test: Employs high-precision equipment to ensure that the cold plate seal is defect-free and eliminates any minor leaks.
  High Pressure and Burst Testing: Simulate extreme working conditions to verify the structural integrity of cold plates under ultra-high pressures, ensuring safety.
    Adhesive Strength Tensile Test: Destructive testing ensures that the bond strength of the fin to the base plate meets the design standards.
  Thermal Resistance and Uniformity Testing: Accurately measure the overall thermal resistance and surface temperature distribution of the cold plate to ensure that the heat dissipation performance meets the standards.

Winshare Bonded Fin Cold Plate Application Fields

Power electronics

IGBT modules, frequency converters, inverters

Data centers

CPU, GPU, HPC clusters, liquid-cooled servers

New energy vehicles

Battery packs, electronic control units (ECUs), power semiconductors

Industrial automation

Industrial control cabinets, robot drives, laser equipment

Medical devices

Magnetic Resonance (MRI), CT, X-ray Equipment

High-power LED lighting

stage lights, street lights, professional photography lights

Winshare Bonded Fin Cold Plates Customization Process:

From Concept to Product

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Requirements analysis and design

We work closely with you to comprehensively assess your cooling needs, including heat load, component size, coolant type, flow rate, pressure drop limits, and environmental requirements, to develop a preliminary design plan.

Thermal Design and CFD Simulation

Our team of engineers will utilize specialized CFD (Computational Fluid Dynamics) simulation software to accurately simulate the performance of cold plates under real-world operating conditions, optimizing fin type, height, density, and runner layout for optimal thermal performance.

Precision machining and bonding

High-precision CNC machine tools are used to process the base plate and cover plate, and the fins are accurately cut. Subsequently, in a dust-free environment, the components are perfectly bonded using vacuum brazing or high-strength epoxy bonding technology.

Rigorous quality inspection

We perform rigorous tests on each cold plate, including helium mass spectrometry leak detection tests, high pressure and burst tests, thermal resistance and uniformity tests, to ensure that the product meets or exceeds design standards in terms of performance and reliability.

Surface Treatment & Delivery

According to customer requirements, various surface treatments such as nickel plating and anodizing are provided to enhance corrosion resistance. Finally, the product is finely packaged and delivered to you on time.

Bonded Fin Cold Plate Frequently Asked Questions (FAQs)

Q What is the difference between bonded fin cold plate and deep hole drilled cold plate?

A Deep hole drilling cold plate runners are smooth, mainly relying on fluid convection heat transfer, but cannot increase the internal surface area. Bonded fin cold plates greatly increase the heat transfer surface area with high-density fins, providing better thermal performance in most cases. At the same time, the runner design of the bonded cold plate is more flexible and the cost is more advantageous.
Q Is the bonding strength of the fins to the base plate reliable?

A Our bonding technology is very reliable. Our vacuum brazing process creates metallurgical grade bonds with extremely high strength and durability. Combined with rigorous bond strength tensile testing and high-pressure testing, our products are built to withstand long-term demanding applications.
Q What is the production cycle of Bonded Fin Cold Plate?

A The production cycle depends on the specific design complexity, material availability, and order volume. We have an efficient production management process, usually 2-4 weeks for sample production and 4-8 weeks for mass production. It is recommended that you provide detailed design drawings, and we will provide you with an accurate delivery estimate.
Q Can you provide design consulting and simulation services?

A Yes, we offer a full range of services, from design concept to finished product delivery. If you're unsure which cold plate solution is best for your application, our team of engineers will provide professional technical consultation and CFD simulation services to help you find the best solution.

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