Case Study: Aluminum Vapor Chamber (ALVC) Thermal Solution for Grid Control Box
Time：
2026-08-20
source:
Case Study: Aluminum Vapor Chamber (ALVC) Thermal Solution for Grid Control Box
Meta Description
This case details our custom ALVC passive cooling design for a grid control box, delivering reliable thermal performance under high ambient temperature without enlarging the heat sink or adding active cooling.
Project Background
Our customer required a compact passive cooling solution for a 6W power module inside a grid control box. The core constraint: junction temperature must stay below 100°C at 70°C ambient temperature.
Instead of upsizing heat sinks or adopting fan-based active cooling, ALVC’s engineering team delivered a tailored thermal stack built around an aluminum vapor chamber.
Design Specifications
- Heat Load: 6W
- Ambient Temperature: 70°C
- Junction Temperature Limit: <100°C
- Enclosure Material: Aluminum 6063
- Custom ALVC Dimension: 90 × 50 × 3 mm, thermal conductivity up to 5000 W/m·K
- Stack-up: Power core → Thermal grease → ALVC → Aluminum heat sink → Al 6063 case
CFD Validation & Result
Pre-production CFD simulation verified the thermal performance:
✅ Maximum core junction temperature: 89.4°C
✅ 10.6°C safety margin, fully meets the customer’s thermal target
✅ Compact, lightweight passive structure with no extra active components
Key Value
Aluminum vapor chambers deliver superior heat spreading to eliminate hotspots in sealed, space-constrained electronics. This passive thermal architecture is ideal for industrial equipment requiring high reliability, minimal maintenance and restricted enclosure size.
Target Application Areas
- Grid control systems
- Power electronics
- Industrial automation
- Energy storage systems
- EV power modules
- Telecom equipment
- Edge & AI computing
At ALVC, we deliver full thermal design services — from requirement definition and CFD simulation, prototype validation through to mass production — rather than only supplying thermal components.
If you are facing thermal bottlenecks in your enclosed power electronics, contact our team to explore a customized vapor chamber solution.
Key words：
NEWS
Contact Us
WhatApp: +86 13534194131
Phone: +86 13534194131
E-mail : riken@alvcfactory.com
Factory Add: 3rd Industrial Zone, Tiantou Hengli Town, Dongguang City Guangdong Province China.
With the expertise and agility of industry leaders, we have the ability to drive innovation to influence our customers and partners.
Contact UsContact us
WeChat:+86 135 3419 4131
Office Add: Room 802A, Tower A, Block 3, Tian’an Cyber Park, Huangge Road, Longgang District, Shenzhen City, Guangdong Province China.
Factory Add: 3rd Industrial Zone, Tiantou Hengli Town, Dongguang City Guangdong Province China.
