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6. Thermal Performance Information Design Guide & Applications Manual Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Simplified thermal management is one of the benefits of using Vicor converters. High operating efficiency minimizes heat loss, and the low-profile package features an easily accessible, electrically isolated thermal interface surface. Proper thermal management pays dividends in terms of improved converter and system MTBFs, smaller size, and lower product lifecycle costs. The following pages provide guidelines for achieving effective thermal management of Vicor converters. Consideration should be given to the module baseplate temperature during operation. The maximum baseplate temperature specification for Maxi, Mini, and Micro is 100°C. Enhanced module cooling can be achieved with free or forced convection by using the appropriate heat sink. The available Vicor heat sinks and thermal interface options are available on the Vicor website. The relevant nomenclature for the tabulated thermal information supplied in this section for the Maxi, Mini and Micro modules is defined as follows: TB = baseplate temperature TA = ambient temperature POUT = module output power PIN = module input power h = module efficiency = POUT / PIN PDISS = module power dissipation = PIN – POUT = (1/η – 1) • POUT Supplied thermal resistance values: θBS = baseplate-to-heatsink thermal resistance θBA = baseplate-to-ambient thermal resistance Basis of output power versus ambient temperature derating curves: TA MAX = TBMAX – θBA • PDISS = TBMAX – θBA • (1/η – 1) • POUT Additional Thermal Data The following pages contain temperature derating curves. For additional thermal data, see the following link: https://asp.vicorpower.com/calculators/calculators.asp?calc=5 Maxi, Mini, Micro Design Guide Rev 5.6 Page 26 of 87 07/2022 6. Thermal Performance Information Design Guide & Applications Manual Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Thermal Performance Curves (Maxi) heat sink fins. Actual airflow through the fins should be verified. For purposes of heat sink calculation, assume efficiencies listed on Maxi data sheets. Use as a design guide only. Verify final design by actual temperature measurement. Table Usage: The forced convection thermal impedance data shown in the tables on pages 27 – 29 assumes airflow through the Maxi θBA (Baseplate-to-Ambient Thermal Resistance Values) vs. Airflow θBS = 0.07°C/W Baseplate 0.9in Longitudinal Fins 0.9in Transverse Fins 0.4in Longitudinal Fins 0.4in Transverse Fins Free Air 4.98 2.89 2.24 3.72 3.49 200LFM 3.23 1.30 1.02 2.14 1.53 400LFM 2.17 0.90 0.72 1.48 1.08 600LFM 1.73 0.72 0.60 1.10 0.87 800LFM 1.46 0.59 0.51 0.86 0.70 1,000LFM 1.27 0.51 0.44 0.71 0.60 1,200LFM 1.14 0.46 0.41 Curves - 4" Heat Sink 2V Maxi Thermal Performance 0.61 0.55 2V Maxi Thermal Performance Curves - No Heat sink 2V Maxi Thermal Performance Curves - 9" Heat Sink Maxi Output Power vs. Ambient Temperature De-rating Curves 0.4in [10,1mm] Heat Sink 140 120 120 120 250 200 200 150 350 300 300 300 100 95 90 85 80 75 70 65 60 55 50 45 40 100 100 95 90 85 80 75 70 65 60 55 50 85 90 95 100 90 95 100 75 70 65 60 55 50 45 40 35 30 300 200 600LFM Maxi, Mini, Micro Design Guide Rev 5.6 Page 27 of 87 07/2022 75 70 65 60 55 50 45 40 35 25 20 5 15 Ambient Temperature (°C) Ambient Temperature (°C) 400LFM 10 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 0 Ambient Temperature (°C) 200LFM 400 100 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 0 25 0 20 100 5 100 85 200 80 300 10 200 400 80 500 Power Output (Watts) 600 500 Power Output (Watts) 600 500 15 25 0 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 10 0 100 Ambient Temperature (°C) 600 10 12 - 48V Maxi Thermal Performance Curves - .9" Heat Sink 20 0 12 - 48V Maxi Thermal Performance Curves - .4" Heat Sink Ambient Temperature (°C) 300 45 50 Ambient Temperature (°C) 400 40 100 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 0 10 12 - 48V Maxi Thermal Performance Curves - No Heat Sink 35 150 50 0 25 200 30 50 150 250 5 100 200 15 150 250 10 200 Output Power (Watts) 400 350 Output Power (Watts) 400 350 Free Air 20 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 10 0 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 10 100 Ambient Temperature (°C) 400 0 5 0 Ambient Temperature (°C) 250 35 5V Maxi Thermal Performance Curves - .9" Heat Sink 50 0 0 Output Power (Watts) 100 50 Ambient Temperature (°C) Output Power (Watts) 150 15 100 5V Maxi Thermal Performance Curves - .4" Heat Sink 10 5V Maxi Thermal Performance Curves - No Heat Sink Output Power (Watts) 250 200 150 30 Ambient Temperature (°C) 250 100 25 0 95 90 100 85 80 75 70 65 60 55 50 45 40 3.3V Maxi Thermal Performance Curves - .9" Heat Sink Ambient Temperature (°C) Output Power (Watts) Output Power (Watts) 35 30 25 20 5 15 0 10 95 90 100 85 80 75 70 65 60 55 50 45 40 35 30 25 20 0 5 0 15 20 0 10 20 0 12 – 54V 40 20 50 5V 60 20 3.3V Maxi Thermal Performance Curves - .4" Heat Sink 40 80 30 40 60 5 3.3V Maxi Thermal Performance Curves - No Heat Sink 100 0 60 80 15 80 100 10 100 Output Power (Watts) 160 140 Output Power (Watts) 160 140 Ambient Temperature (°C) 3.3V 0.9in [22,8 mm] Heat Sink 160 0 2V Output Power (Watts) Baseplate (No Heat Sink) 800LFM 1000LFM 1200LFM 6. Thermal Performance Information Design Guide & Applications Manual Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Thermal Performance Curves (Mini) heat sink fins. Actual airflow through the fins should be verified. For purposes of heat sink calculation, assume efficiencies listed on Mini data sheets. Use as a design guide only. Verify final design by actual temperature measurement. Table Usage: The forced convection thermal impedance data shown in the tables on pages 27 – 29 assumes airflow through the Mini θBA (Baseplate-to-Ambient Thermal Resistance Values) vs. Airflow θBS = 0.14°C/W Baseplate 0.9in Longitudinal Fins 0.9in Transverse Fins 0.4in Longitudinal Fins 0.4in Transverse Fins Free Air 7.94 4.10 3.93 6.28 6.34 200LFM 4.50 1.72 1.93 2.81 3.00 400LFM 3.20 1.26 1.38 1.98 2.09 600LFM 2.52 1.02 1.06 1.55 1.59 1.31 800LFM 2.15 0.86 0.89 1.24 1,000LFM 1.89 0.75 0.77 1.05 1,200LFM 1.69 0.68 0.70 0.94 2V Mini Thermal Performance Curves - No Heat Sink 2V Mini Thermal Performance Curves - .4" Heat Sink 1.11 0.99 2V Mini Thermal Performance Curves - .9" Heat Sink Mini Output Power vs. Ambient Temperature De-rating Curves Baseplate (No Heat Sink) 100 90 90 80 80 80 30 95 90 100 85 75 70 65 60 55 50 45 40 80 95 100 95 100 95 100 90 90 85 80 75 70 65 60 55 50 45 40 35 65 60 55 50 45 40 35 30 150 100 Ambient Temperature (°C) 400LFM Maxi, Mini, Micro Design Guide Rev 5.6 Page 28 of 87 07/2022 600LFM 800LFM 65 60 55 50 45 40 35 30 25 20 15 5 10 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 10 0 Ambient Temperature (°C) 200LFM 200 50 0 95 100 90 85 80 75 70 65 60 55 50 45 40 35 0 75 100 50 75 150 0 70 200 50 70 250 Output Power (Watts) 300 250 Output Power (Watts) 300 30 25 Ambient Temperature (°C) 250 25 20 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 10 0 Ambient Temperature (°C) 100 30 12 - 48V Mini Thermal Performance Curves - .9" Heat Sink 20 300 20 25 60 40 Ambient Temperature (°C) 15 20 80 12 - 48V Mini Thermal Performance Curves - .4" Heat Sink 0 95 100 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 5 10 15 100 0 150 90 60 20 200 85 80 120 40 12 - 48V Mini Thermal Performance Curves - No Heat Sink 85 100 140 15 60 120 5 80 140 10 100 80 160 120 80 160 Output Power (Watts) 180 160 5 5 Ambient Temperature (°C) 200 10 10 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 0 180 0 5V Mini Thermal Performance Curves - .9" Heat Sink 20 200 140 35 40 180 0 30 60 200 Free Air 25 80 Ambient Temperature (°C) Output Power (Watts) Output Power (Watts) 100 5V Mini Thermal Performance Curves - .4" Heat Sink 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 0 20 0 5 20 15 20 10 Output Power (Watts) 40 20 5V Mini Thermal Performance Curves - No Heat Sink 60 5 60 80 15 80 100 10 100 0 20 0 95 100 90 85 80 75 70 65 60 55 50 45 40 35 30 120 Output Power (Watts) 140 120 0 Output Power (Watts) 140 40 Output Power (Watts) Ambient Temperature (°C) Ambient Temperature (°C) 120 20 5 0 0 95 90 10 140 40 3.3V Mini Thermal Performance Curves - .9" Heat Sink 30 10 Ambient Temperature (°C) 12 – 54V 40 20 Ambient Temperature (°C) 5V 50 0 100 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 10 0 0 60 15 10 70 20 25 3.3V Mini Thermal Performance Curves - No Heat Sink 3.3V Mini Thermal Performance Curves - .4" Heat Sink 40 20 30 50 5 40 60 15 50 10 60 70 10 Output Power (Watts) 70 Output Power (Watts) 100 90 20 3.3V 0.9in [22,8 mm] Heat Sink 100 Output Power (Watts) 2V 0.4in [10,1mm] Heat Sink Ambient Temperature (°C) 1000LFM 1200LFM 6. Thermal Performance Information Design Guide & Applications Manual Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Thermal Performance Curves (Micro) heat sink fins. Actual airflow through the fins should be verified. For purposes of heat sink calculation, assume efficiencies listed on Micro data sheets. Use as a design guide only. Verify final design by actual temperature measurement. Table Usage: The forced convection thermal impedance data shown in the tables on pages 27 – 29 assumes airflow through the Micro θBA (Baseplate-to-Ambient Thermal Resistance Values) vs. Airflow θBS = 0.21°C/W Baseplate 0.9in Longitudinal Fins 0.9in Transverse Fins 0.4in Longitudinal Fins 0.4in Transverse Fins Free Air 10.90 5.37 5.04 7.77 7.76 200LFM 6.90 2.51 2.31 3.87 3.58 400LFM 4.78 1.79 1.68 2.68 2.52 600LFM 3.74 1.42 1.31 2.13 2.01 800LFM 3.15 1.20 1.10 1.78 1.67 1,000LFM 2.79 1.06 0.97 1.48 1.45 2.49 0.93 0.88 1.32 1,200LFM 2V Micro Thermal Performance Curves - .4" Heat Sink 2V Micro Thermal Performance Curves - No Heat Sink 1.29 2V Micro Thermal Performance Curves - .9" Heat Sink Micro Output Power vs. Ambient Temperature De-rating Curves 0.4in [10,1mm] Heat Sink 50 45 45 40 40 40 10 5 40 30 20 80 60 50 40 30 10 95 90 85 80 75 70 65 60 55 100 100 95 90 85 80 75 70 65 60 55 50 45 40 35 80 85 90 95 100 85 90 95 100 75 75 80 70 70 65 60 55 50 45 40 35 25 20 80 60 40 400LFM Maxi, Mini, Micro Design Guide Rev 5.6 Page 29 of 87 07/2022 600LFM Ambient Temperature (°C) 800LFM 1000LFM 65 60 55 50 45 40 35 30 25 20 15 5 0 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 Ambient Temperature (°C) 10 Ambient Temperature (°C) 200LFM 100 20 25 0 100 95 90 85 80 75 70 65 60 55 50 45 0 40 0 35 20 30 20 25 Output Power (Watts) 40 20 40 60 5 60 80 15 80 100 10 Output Power (Watts) 120 100 20 15 Ambient Temperature (°C) 140 15 5 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 10 Ambient Temperature (°C) 120 5 30 12 - 48V Micro Thermal Performance Curves - .9" Heat Sink 140 10 25 30 120 0 20 40 140 Free Air 15 50 0 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 5 10 0 12 - 48V Micro Thermal Performance Curves - .4" Heat Sink 0 Ambient Temperature (°C) Output Power (Watts) 60 20 10 0 70 10 Output Power (Watts) 70 20 12 - 48V Micro Thermal Performance Curves - No Heat Sink 10 Output Power (Watts) 90 Output Power (Watts) 100 80 20 5 Ambient Temperature (°C) 90 30 10 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 0 Ambient Temperature (°C) 100 40 50 20 80 50 5V Micro Thermal Performance Curves - .9" Heat Sink 30 90 60 45 40 100 70 40 50 10 5V Micro Thermal Performance Curves - .4" Heat Sink 0 100 95 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 0 15 10 0 10 10 15 20 50 10 5V Micro Thermal Performance Curves - No Heat Sink Output Power (Watts) 60 Output Power (Watts) 70 60 40 35 Ambient Temperature (°C) 70 50 30 0 Ambient Temperature (°C) 60 30 25 95 90 0 100 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 0 95 90 100 85 80 75 70 65 60 55 50 45 40 35 30 25 20 5 15 10 0 15 70 0 Output Power (Watts) 3.3V Micro Thermal Performance Curves - .9 Heat Sink 20 0 Ambient Temperature (°C) 12 – 54V 25 5 Ambient Temperature (°C) 5V 30 10 3.3V Micro Thermal Performance Curves - No Heat Sink 0 3.3V Micro Thermal Performance Curves - .4" Heat Sink 15 10 5 20 20 15 25 30 20 35 5 25 30 15 30 35 10 35 Output Power (Watts) 50 45 10 3.3V 0.9in [22,8 mm] Heat Sink 50 Output Power (Watts) 2V Output Power (Watts) Baseplate (No Heat Sink) 1200LFM 6. Thermal Performance Information Design Guide & Applications Manual Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Typical Examples — Thermal Equations (Maxi, Mini, Micro) Example 2 Example 1 Determine the maximum ambient for a Mini module with a 0.9in [22,8mm] heat sink in 400LFM of airflow delivering 200W at 5V. Determine the maximum output power for a Maxi module without a heat sink delivering 5V in 400LFM airflow at a maximum ambient temperature of 40ºC. Maximum output power = TBMAX – TA MAX / [θBA • (1/η – 1)] ( ) 5V Mini Thermal Performance Curves - .9" Heat Sink From the output power versus ambient temperature chart for the 5VOUT Mini with a 0.9in [22,8mm] heat sink, the 200W at 400LFM data point results in a TAMAX of approximately 48ºC. TBMAX = 100ºC TAMAX = 40ºC 200 180 For Maxi module without a heat sink @ 400LFM, θBA = 2.17ºC/W Output Power (Watts) 160 For the 5V Maxi module the typical value for η = 0.83 Maximum output power = (100 – 40) / [2.17 (1/0.83 – 1)] ~135W Or, the same answer could be obtained by using the output power versus ambient temperature de-rating curves for the Maxi modules. θBA = (100 – 40) / [400 (1/0.83 – 1)] = 0.73ºC/W 120 100 80 60 40 For the case with no heat sink the baseplate chart for the 5V module would be used. At a 40ºC ambient and 400LFM airflow this chart indicates a maximum output power of approximately 135W. For full output power of 400W the required thermal resistance is; 140 20 Ambient Temperature (°C) Figure 6.1 — 5V Mini with 0.9in [22,8mm] heat sink What size heat sink would be necessary to operate at full output power (400W) under the same conditions? From the θba versus airflow charts for the Maxi, the thermal resistance at 400LFM airflow requires the use of a 0.9in [22,8mm] transverse fin heat sink. Maxi, Mini, Micro Design Guide Rev 5.6 Page 30 of 87 07/2022 95 100 90 85 80 75 70 65 60 55 50 45 40 35 30 25 20 15 5 10 0 0 6. Thermal Performance Information Design Guide & Applications Manual Maxi, Mini, Micro Family DC-DC Converters and Configurable Power Supplies Thermal Management Accessories All parts are RoHS compliant unless otherwise noted. Transverse Fins Longitudinal Fins Maxi Heat Sinks Mini Heat Sinks Micro Heat Sinks Threaded Through Hole Threaded Through Hole Threaded Through Hole 0.4in [10,1mm] Fin P/N 30482 0.4in [10,1mm] Fin P/N 30718 0.4in [10,1mm] Fin P/N 32188 0.4in [10,1mm] Fin P/N 30195 0.4in [10,1mm] Fin P/N 32174 0.4in [10,1mm] Fin P/N 30719 0.9in [22,8mm] Fin P/N 30188 0.9in [22,8mm] Fin P/N 30181 0.9in [22,8mm] Fin P/N 30189 0.9in [22,8mm] Fin P/N 30182 0.9in [22,8mm] Fin P/N 30190 0.9in [22,8mm] Fin P/N 30183 0.4in [10,1mm] Fin P/N 30778 0.4in [10,1mm] Fin P/N 30720 0.4in [10,1mm] Fin P/N 30184 0.4in [10,1mm] Fin P/N 30721 0.4in [10,1mm] Fin P/N 32173 0.4in [10,1mm] Fin P/N 30722 0.9in [22,8mm] Fin P/N 30196 0.9in [22,8mm] Fin P/N 30723 0.9in [22,8mm] Fin P/N 30269 0.9in [22,8mm] Fin P/N 30724 0.9in [22,8mm] Fin P/N 30270 0.9in [22,8mm] Fin P/N 30725 Low-profile Side-fin Heat Sinks Standoffs and Screws Height only 0.125in [3,17mm] above module baseplate [a] Bulk and single-module kits compatible with all standard mounting configurations. 0.55in [13,97mm] Side Fins P/N 30096 0.55in [13,97mm] Side Fins P/N 32190 0.55in [13,97mm] Side Fins P/N 30095 See the specific products on the Vicor website for more information. ThermMate Thermal Pads 20263 For use with Vicor modules, ThermMate thermal pads are a “dry” alternative to thermal compound and are pre-cut to the outline dimensions of the module. Thermal pad 20265 [a] 20264 Maxi (10pc. pkg.) Mini (10pc. pkg.) Micro (10pc. pkg.) Part Number Thickness 20263 20264 20265 0.007” [0,177mm] 0.007” [0,177mm] 0.007” [0,177mm] For thermal curves of low-profile side-fin heat sinks and on-line capability for thermal curve calculations, see the following link: https://asp.vicorpower.com/calculators/calculators.asp?calc=5 Maxi, Mini, Micro Design Guide Rev 5.6 Page 31 of 87 07/2022