Air Cooled Heat Sink

COUGAR ELECTRONICS can design and produce high performance air cooled heat sinks for advanced applications.

General principle

Air cooled heat sinks allows an exchange between a surface, heated by an electronic component, and the air.

There are two kind of heat sinks :

Several manufacturing technologies exist :

  • Extrusion
  • Bounded fins
  • Brazed fins
  • Machining into raw material

Following the thermal parameters of the application, COUGAR ELECTRONICS will help you to find the optimal cost / efficiency solution.


Technical datas

  • Material: Aluminum 6060/6061/6082
  • Thermal resistance: 15 to 35°C/kW
  • Surface treatment: anodizing / suretec / nickel plating…


  • Simplicity
  • Cost


  • Natural convection heat sink
  • Brazed radiator
  • HSHP radiator

Insulated Heat Sink

COUGAR ELECTRONICS is distributing on US market CECLA METAL PROCESS’ unique know-how in the manufacturing of high tension electrical insulated cooling solution.


In some high tension configurations of multi-scale power converters, it’s necessary to use oversized electronic semiconductors in order to respect dielectric norms of the application, particularly in railway application.

Electrical insulated cooler allow to avoid the oversizing of the components in multi-scales’ topologies by adding insulation between the component its cooling system.


  • Economic on high tension multi-scale converters
  • Appropriate shape and dimensions for your component topology
  • Appropriate for on-board using, especially in the railway industry

Technical caracteristics

  • Insulation : up to20kV
  • Thermal resistance : 15 to 55°C/kW
  • Fire-Smoke qualification : ULV0

Heat Sink with embedded Heat Pipes

COUGAR ELECTRONICS is distributing on US market CECLA METAL PROCESS’ range of HSHP heat sink. This performing solution allow to reduce weight and improve compactness by spreading the heat with heat pipe in the base plate of the heat sink.


The typical application of heat sink with embedded heat pipes is high density power semiconductors. Those heat sinks, can also be used to increase the maximum power of a heat sink, without changing the size. The heat pipe by their high thermal conductivity will act as heat spreader and allow all heat sink working better,


  • Light and compactness
  • Performing solution, without change of size
  • Able do dissipate high density thermal flux semidonductors

heat sink air cooled

Heat pipes coolers are like the Loch Ness monster... lot's of people are speaking about, but few people have really tested them! This technology sounds a little bit mysterious for people coming from a pure electronics background ! How can such a thing (looking like a basic copper tube), would be able to convey something like 1000 time more calories than the best typical thermal conductor in electronics : copper ! You will certainly find the answer in our dedicated page to the heat pipe functioning, or to heat pipe page on wikipedia, if you want to go deeper in the subject. [caption id="attachment_1877" align="aligncenter" width="685"]Heat Pipe functionning Heat Pipe functionning[/caption]

Thermal management challenges in power electronics

As it was explained in our market analysis article about SIC semiconductors, power electronics is currently at the beginning of a revolution. Semiconductors are now able to work up to incredibly high frequency (50 to 100kHz), with excellent efficiency, and low losses. Because working at high frequency leads to reducing size and weight, this revolution increasesthe density of power losses. New thermal management challenges are in front of us. But good news, heat pipes are here to help solving them ! Here are the main reasons why ?

Heat pipe advantages

  • High thermal conductivity. Because heat pipes are using one of the most efficient way to convey calories : phase change, their high thermal conductivity will be the best advantage to solve your thermal management issues.
[caption id="attachment_1880" align="aligncenter" width="300"]Heat Pipe thermal conductivity simulation Heat Pipe thermal conductivity simulation[/caption]
  • Temperature range. It is mainly depending from the working fluid inside the heat pipe. Considering most of the power electronics application going from 50 to 200 degC, you will not find a better fluid than water. Good news, water is not dangerous and not explosive as you may know... Bad news, water is electrically conductor as you may know too. Electronics designer never sleeps soundly when water flows close to their components ! If you feel a bit of apprehension, read our next point.
  • Reliability. Heat pipes are excellent in reliability because they use no mooving mechanical parts and need no energy like electricity. No worry about maintaining the motor or the filter of your pump like in a cooling loop. The difference of temperature is the only "motor" which garanty an endless  functionning. Heat pipes are commonly used in aerospace application and railway, where life cycle of the product can be up to 50 years !
[caption id="attachment_1861" align="aligncenter" width="300"]Railway Heat Pipe Cooler Railway Heat Pipe Cooler[/caption] We hope this article have contributed to better understanding of heat pipes.

Contact us

For any question, enquiry, contact COUGAR ELECTRONICS here. Our thermal engineers will be happy to help :-)