Heat Sink for a 100 kW Energy Storage PCS

Requirement

The customer builds 100 kW class energy storage converters with power stacks mounted one above the other and fixed bottom-to-top airflow. Their previous bonded-fin design loosened during vibration testing and ran hotter than planned. The target was to cut module temperature rise without changing the cabinet, keeping sink thickness under 45 mm.

Our approach

We moved to a one-piece skived design, removing the bonded interface between base and fins. Fins are 22 mm high at 2 mm pitch, aligned with the cabinet airflow. The base follows the IGBT module hole pattern and includes a channel for the temperature sensor harness. Three samples with different fin heights were supplied for comparison before the customer chose the final geometry.

Delivery and inspection

First article shipped with full dimensional and flatness reports; critical dimensions sampled in production. Anodized body with a mill-finish mounting face so thermal pads seat properly.

Project summary

Cabinet-level temperature testing confirmed the module stayed within design margin, with sink thickness at 42 mm. The loosening issue seen with bonded fins no longer occurs. The same construction is now used across the series with only the hole pattern changed.