New zipper fin heat sinks from Advanced Thermal Solutions, Inc. (ATS) are protecting thousands of components from the dangers of excess heat at a lower cost than other high fin density heat sink types. Zipper fins are machined from thin sheet metal, typically aluminum or copper, and are formed into custom shapes. The sheets are designed to interlock with a very narrow space between their layers. The fin assembly is wave soldered to a metal base forming a very rigid, lightweight heat sink.
The zipper fin production process yields a lower cost heat sink than bonded fin designs. This is mainly because bonded heat sinks require more expensive tooling to manufacture. Zipper fin heat sinks can also be made in high aspect ratio fin profiles, enabling taller, thinner and more tightly packed fins for higher cooling performance.
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Zipper fin heat sinks allow the combined use of copper and aluminum materials. In these designs, the copper base allows for optimal heat spreading while the aluminum fins ensure the heat sink will be lightweight. With the benefits of higher performance and lighter weight, ATS zipper fin heat sinks can be used to cool LEDs, as well as hot components in telecom, datacom, military and embedded electronics industries.
source: http://www.powerpulse.net/story.php?storyID=31772
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