Non-Uniform Height And Density Fin Design For Heat Sink

Abstract

A heat sink includes a heat sink plate and a heat generating electrical component mounted to a first side of the heat sink plate. Fins are connected and oriented perpendicular to a second side of the heat sink plate. The fins include a maximum height fin positioned proximate to the electrical component, and a minimum height fin spatially separated from the maximum height fin and the electrical component. A first group of fins is positioned between the maximum and minimum height fins. Each fin of the first group progressively decreases in height from a height of the maximum height fin to a height of the minimum height fin. A first spacing between the maximum height fin and a proximate one of the fins of the first group is less than a second spacing between any two consecutive ones of the first group of fins.

1 . A heat sink, comprising:
 a heat sink plate;   at least one heat generating electrical component mounted to a first side of the heat sink plate;   a plurality of fins connected and oriented perpendicular to a second side of the heat sink plate, the plurality of fins including:
 at least one maximum height fin positioned on the second side proximate to a position on the first side of the electrical component; 
 a minimum height fin spatially separated from the at least one maximum height fin and the electrical component; and 
 a first group of fins positioned between the at least one maximum height fin and the minimum height fin, each fin of the first group of fins progressively decreasing in height from a height of the at least one maximum height fin to a height of the minimum height fin. 
   
     
     
         2 . The heat sink of  claim 1 , further including first and second end walls connected to and oriented perpendicular to the heat sink plate wherein the plurality of fins is positioned between the first and second end walls. 
     
     
         3 . The heat sink of  claim 2 , further including an electrical component support directly connected to the first side of the heat sink plate between the first and second end walls, wherein the at least one heat generating electrical component is directly mounted to the electrical component support. 
     
     
         4 . The heat sink of  claim 2 , wherein the plurality of fins is positioned between the first and second end walls having individual ones of the plurality of fins homogenously connected to the heat sink plate. 
     
     
         5 . The heat sink of  claim 2 , wherein the at least one minimum height fin comprises first and second minimum height fins each homogenously connected to the second side of the heat sink plate proximate to one of the first and second end walls. 
     
     
         6 . The heat sink of  claim 1 , wherein the at least one heat generating electrical component is directly mounted in a slot created in the first side of the heat sink plate between the first and second end walls. 
     
     
         7 . The heat sink of  claim 2 , further including:
 a second group of fins;   a second minimum height fin positioned proximate the second end wall;   wherein the at least one maximum height fin includes at least first and second maximum height fins positioned proximate to each other; and   wherein consecutive fins of the second group of fins progressively decrease in height from a height of the second maximum height fin to a height of the second minimum height fin.   
     
     
         8 . The heat sink of  claim 7 , further including a first spacing between the first and second maximum height fins being less than or equal to a second spacing between the second maximum height fin and a proximate one of the fins of the second group of fins. 
     
     
         9 . The heat sink of  claim 1 , further including a plurality of raised elements created on opposed sides of all fins of the plurality of fins. 
     
     
         10 . The heat sink of  claim 9 , wherein the raised elements have a height ranging from approximately fifty percent to sixty percent of a fin thickness. 
     
     
         11 . The heat sink of  claim 1 ,
 wherein the at least one maximum height fin includes at least first and second maximum height fins positioned proximate to each other; and   wherein a first spacing between the first and second maximum height fins and a proximate one of the fins of the first group of fins is less than or equal to a second spacing between any two consecutive ones of the first group of fins.   
     
     
         12 . The heat sink of  claim 1 ,
 wherein the at least one maximum height fin includes at least first and second maximum height fins positioned proximate to each other; and   wherein a first spacing between the first and second maximum height fins and a proximate one of the fins of the first group of fins is greater than or equal to a second spacing between any two consecutive ones of the first group of fins.   
     
     
         13 . A heat sink, comprising:
 a heat sink plate;   an electrical component support directly connected to a first side of the heat sink plate having at least one heat generating electrical component mounted to the electrical component support;   a plurality of fins connected and oriented perpendicular to a second side of the heat sink plate, the plurality of fins including:
 at least one maximum height fin positioned proximate to the electrical component; 
 first and second minimum height fins each oppositely positioned with respect to the at least one maximum height fin and spatially separated from the electrical component; 
 a first group of fins positioned between the at least one maximum height fin and the first minimum height fin, each fin of the first group of fins progressively decreasing in height from a height of the at least one maximum height fin to a height of the first minimum height fin; and 
 a second group of fins positioned between the at least one maximum height fin and the second minimum height fin, each fin of the second group of fins progressively decreasing in height from the height of the at least one maximum height fin to a height of the second minimum height fin. 
   
     
     
         14 . The heat sink of  claim 13 , further including a first spacing between the at least one maximum height fin and a proximate one of the fins of the first group of fins being less that a second spacing between any two consecutive ones of the first group of fins. 
     
     
         15 . The heat sink of  claim 14 , further including a second spacing between the at least one maximum height fin and a proximate one of the fins of the second group of fins being less that a third spacing between any two consecutive ones of the second group of fins. 
     
     
         16 . The heat sink of  claim 15 , wherein the at least one maximum height fin includes first, second, and third maximum height fins, each having a height equal to the other ones of the maximum height fins. 
     
     
         17 . The heat sink of  claim 16 , further including a third spacing between the first and second maximum height fins and between the second and third maximum height fins, the third spacing being less than the first and second spacings. 
     
     
         18 . The heat sink of  claim 13 , further including first and second end walls connected to and oriented perpendicular to the heat sink plate wherein the plurality of fins is positioned between the first and second end walls. 
     
     
         19 . A heat sink, comprising:
 a heat sink plate;   at least one heat generating electrical component mounted to a first side of the heat sink plate;   a plurality of fins connected and oriented perpendicular to a second side of the heat sink plate, the plurality of fins including:
 at least one maximum height fin positioned proximate to the at least one electrical component; 
 at least one minimum height fin spatially separated from the at least one maximum height fin and the at least one electrical component; 
 a first group of fins positioned between the at least one maximum height fin and the at least one minimum height fin, each fin of the first group of fins progressively decreasing in height from a height of the at least one maximum height fin to a height of the at least one minimum height fin; and 
 a plurality of raised elements created on opposed sides of each fin of the plurality of fins. 
   
     
     
         20 . The heat sink of  claim 19 , wherein the raised elements define waves having a wave height ranging from approximately fifty percent to sixty percent of a fin thickness. 
     
     
         21 . The heat sink of  claim 19 , wherein the waves are angularly oriented with respect to a transverse direction of each fin. 
     
     
         22 . The heat sink of  claim 21 , wherein the waves are oriented from approximately 120° to approximately 150° with respect to a plane centrally defined through the heat sink plate. 
     
     
         23 . The heat sink of  claim 21 , wherein the waves are oriented in a transverse direction with respect to a height of the fins. 
     
     
         24 . The heat sink of  claim 21 , wherein the at least one heat generating electrical component comprises two spatially separated heat generating electrical components, the at least one maximum height fin includes two maximum height fins having an individual one of the two maximum height fins positioned proximate to one of the two maximum height fins, and the plurality of fins defines a sinusoidal shape. 
     
     
         25 . The heat sink of  claim 19 , wherein the raised elements define a plurality of oppositely facing ribs on each fin. 
     
     
         26 . The heat sink of  claim 25 , wherein the ribs have a rib height ranging from approximately fifty percent to sixty percent of a fin thickness. 
     
     
         27 . A heat sink assembly, comprising:
 a heat sink plate;   at least one heat generating electrical component mounted to a first side of the heat sink plate;   a plurality of fins connected and oriented perpendicular to a second side of the heat sink plate, the plurality of fins including:
 a maximum height fin positioned proximate to the electrical component; 
 a minimum height fin spatially separated from the maximum height fin and the electrical component; 
 a first group of fins positioned between the maximum height fin and the minimum height fin, each fin of the first group of fins progressively decreasing in height from a height of the maximum height fin to a height of the minimum height fin; and 
   a cover box releasably connected to the heat sink plate and adapted to enclose the at least one heat generating electrical component and the first side of the heat sink plate.   
     
     
         28 . The heat sink assembly of  claim 27 , wherein the heat sink plate further includes at least one engagement slot located on the second side adapted to fastenably connect the cover box to the heat sink plate. 
     
     
         29 . The heat sink assembly of  claim 28 , wherein the at least one engagement slot is defined between opposed tapered surfaces extending away from the at least one engagement slot. 
     
     
         30 . The heat sink assembly of  claim 28 , further including first and second end walls connected to and oriented perpendicular to the heat sink plate wherein the plurality of fins is positioned between the first and second end walls, the heat sink plate and the first and second end walls together with the cover box collectively defining an outer perimeter surface enclosing the at least one heat generating electrical component. 
     
     
         31 . A method for arranging a plurality of cooling fins of a heat sink, the heat sink including a heat sink plate, at least one heat generating electrical component, and a plurality of fins including a maximum height fin, a minimum height fin, and a first group of fins, the method comprising:
 mounting the at least one heat generating electrical component to a first side of the heat sink plate;   extending the plurality of fins perpendicular to a second side of the heat sink plate;   positioning the maximum height fin proximate to the electrical component;   spatially separating the minimum height fin from the maximum height fin and the electrical component;   interposing the first group of fins between the maximum height fin and the minimum height fin; and   progressively decreasing a height of each fin of the first group of fins from a height of the maximum height fin to a height of the minimum height fin.   
     
     
         32 . The method of  claim 31 , further comprising:
 separating the maximum height fin from a proximate one of the fins of the first group of fins by a first spacing; and   separating any two consecutive ones of the first group of fins by a second spacing greater than or equal to the first spacing.