Automotive

With the rapid advancement of new energy vehicles and intelligent vehicles, the quantity and power density of in-vehicle electronic equipment continue to rise, making thermal management an increasingly prominent challenge. Automotive electronics encompass motor controllers, inverters, DC/DC converters, battery management systems (BMS), on-board chargers (OBC), ADAS domain controllers, and LED headlamps. These core components generate substantial heat during prolonged operation and under high-load conditions. Inadequate thermal design may lead to component overheating, efficiency degradation, or even failure, thereby compromising overall vehicle performance and safety.

The complex automotive operating environment imposes stringent demands on heat sinks. Vehicles must maintain stable performance across an extensive temperature range, from extreme cold to intense heat, requiring heat sinks to withstand thermal cycling from -40°C to 125°C or higher. Furthermore, frequent vibrations and impacts during operation necessitate high mechanical strength and fatigue resistance to prevent fin fractures or solder joint failure. Vehicle electronics are weight-sensitive, necessitating radiators that are as lightweight as possible to reduce overall energy consumption and extend driving range.

Inverters and motor controllers predominantly utilise large-scale extruded or cold-forged radiators, integrated with heat pipes or heat spreaders. This configuration rapidly transfers heat from power modules to cooling fins, dissipating it via natural convection or forced air cooling. For high-performance vehicles or heavy-duty applications, liquid-cooled plate solutions are employed, circulating coolant to remove heat and ensure power modules operate within optimal temperature ranges. LED vehicle lamps commonly employ die-cast monolithic heat sinks or pin-fin heat sinks, ensuring stable luminous efficiency while meeting aesthetic and lightweight requirements. BMS and OBC units, being more compact, typically utilise CNC-machined miniature heat sinks or aluminium enclosures, with surface treatments enhancing corrosion resistance.