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Old 08-15-2009, 10:02 PM #1
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Default Custom Copper Powder Heatsinks

Would Copper Powder be suitable to use as a heatsink in lasers? I realize it would be very important to seal off the powder once it is poured around the diode/module, as to not interfere with the electronics and not scratch the diode. It seems like it would be much easier and cheaper than having someone custom machine heatsinks for your host of choice.

I am not sure if this is in the right section, but an admin can move it if necessary.


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Old 08-15-2009, 10:13 PM #2
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Default Re: Custom Copper Powder Heatsinks

WELL.....how you going to do this ? sounds interesting but not to fesabile...
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Old 08-16-2009, 01:53 AM #3
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Default Re: Custom Copper Powder Heatsinks

Powder is inherently full of air, and air is a phenomenal insulator.
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Old 08-16-2009, 02:02 AM #4
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Default Re: Custom Copper Powder Heatsinks

So, no go on the powder?
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Old 08-16-2009, 05:30 AM #5
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Default Re: Custom Copper Powder Heatsinks

Melt the powder into copper bar?
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Old 08-16-2009, 05:43 AM #6
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Default Re: Custom Copper Powder Heatsinks

Could work.. but wouldn't bet on it. if you do go ahead with it let us know how it turns out!

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Old 08-16-2009, 02:58 PM #7
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Default Re: Custom Copper Powder Heatsinks

Maybe I could mix it with some thermal adhesive. This way it would be easier to mold and the powder wouldn't be loose. Or maybe just use thermal adhesive around the module. Has anyone tried this before?

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Old 08-16-2009, 05:12 PM #8
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Default Re: Custom Copper Powder Heatsinks

Do that. You should get a nice paste to fill gaps with, but don't use the paste as your primary heatsink. The gaps left by the powder particles provide surface area where heat is allowed to spread to, except you want the surface area to be where outside air can dissipate the heat away from the heatsink. You don't want air to trap the heat inside instead.
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Old 08-16-2009, 06:07 PM #9
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Default Re: Custom Copper Powder Heatsinks

Copper powder will make a very poor thermal conductor due to the air in it, but even mixing in adhesive to fill the gap wouldn't yield a very good thermal conductor. If you would like a castable material, solder (tin/lead) would be a reasonable choice. Its thermal coductivity is about a tenth of that of copper, but still many times better then the best thermal grease/expoxy/adhesive/etc.

Obviously you should not cast the heatsink with the diode in place, but somehow insert it after this have set and cooled down.
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Old 08-16-2009, 11:33 PM #10
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Default Re: Custom Copper Powder Heatsinks

How much air could really be in the copper powder if the copper powder crystals are only 1.8 µm (microns) maximum, in size?
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Old 08-17-2009, 12:17 AM #11
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Default Re: Custom Copper Powder Heatsinks

More than enough to cause problems
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Old 08-18-2009, 04:52 PM #12
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Default Re: Custom Copper Powder Heatsinks

Quote:
Originally Posted by ZRTMWA View Post
How much air could really be in the copper powder if the copper powder crystals are only 1.8 µm (microns) maximum, in size?
No matter how small it is, it wont replace solid copper.
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Old 08-18-2009, 05:03 PM #13
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Default Re: Custom Copper Powder Heatsinks

Quote:
Originally Posted by Meatball View Post
Do that. You should get a nice paste to fill gaps with, but don't use the paste as your primary heatsink. The gaps left by the powder particles provide surface area where heat is allowed to spread to, except you want the surface area to be where outside air can dissipate the heat away from the heatsink. You don't want air to trap the heat inside instead.
Its called, Daguin Frog Juice ^^.
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Old 08-19-2009, 11:21 PM #14
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Default Re: Custom Copper Powder Heatsinks

The copper would probably need to have molecular bonds to ensure proper conduction to remove heat. The powder probably would not be able to acheive what the solid copper (with its molecular bonds) does in removing heat through conduction of the heat.
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Old 08-23-2009, 04:15 AM #15
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Default Re: Custom Copper Powder Heatsinks

what id do is:

Make a crucible
Make a foundry
Make a dirt/clay mold

scrap copper=melted=poured into mold=a nice piece to work with if you make your mold good enough
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Old 08-23-2009, 08:46 AM #16
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Default Re: Custom Copper Powder Heatsinks

More power to your crucible/mold creation. It's cheaper to buy copper rod and cut it with a hacksaw though.
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