ZICOThermal｜Thermal Product Optimization Service
ZICO Thermal offers professional thermal product optimization. Improve cooling efficiency, reduce weight & cut costs for cold plates, TEC modules and liquid cooling assemblies via simulation & real testing. Request a review.
What Product Optimization Services We Provide for Customers
Thermal Performa
We conduct thermal simulation analysis based on the customer’s original structural model, then develop revised designs for side-by-side comparison. The optimal design scheme is determined to improve heat exchange efficiency, eliminate hotspots and lower chip junction temperature. This effectively resolves overheating and thermal throttling issues under high load, balances overall temperature distribution and reduces temperature difference across the surface.
Envelope & Dimension Optimization
We optimize the external dimensions of thermal products to fit limited internal installation space inside equipment and save layout room. For heat sinks, we adopt skived fin technology to expand heat exchange area. Combined with heat pipes, cooling efficiency can be significantly improved. This allows reduction in the overall weight and size of heat sinks. We also carry out optimized design for airflow channels of the whole system to lower air flow resistance.
Internal Thermoelectric Leg & Module Structure Optimization
We optimize the aspect ratio, height and cross-sectional area of P/N-type thermoelectric legs to balance electrical resistance and back heat leakage, improving COP and achievable temperature difference. We refine copper electrode layout, ceramic substrate selection and soldering interface design to reduce contact thermal resistance and Joule heat, and mitigate thermal stress under thermal cycling conditions. Custom arrangement and multi-stage cascaded TEC structural solutions are available for applications requiring high precision and large temperature difference.
External Drive & Temperature Control Circuit Optimization
We optimize H-bridge bidirectional power drive circuits, PWM parameters and closed-loop PID temperature control algorithms to reduce current ripple and power loss, enabling stable, high-precision temperature regulation. Comprehensive protection logic can be configured to extend the continuous operating lifespan of TEC modules.
Standard Product Optimization Workflow
1. Baseline Data Collection & Objective Definition
We gather original drawings, historical test data, installation constraints, power consumption parameters and field failure feedback. Together with your engineering team, we confirm optimization targets, including improved cooling efficiency, weight reduction, cost control or enhanced reliability.
2. Baseline Simulation & Thermal Bottleneck Identification
We build simulation models of the original design using Icepak and Flotherm to accurately locate hotspots, high thermal resistance zones, fluid stagnant regions and excessive pressure loss.
3,Delivery of Multiple Alternative Optimized Designs
We provide multiple revised structural solutions supported by comparative simulation data. Each option includes projected thermal performance indicators, estimated manufacturing costs and processing complexity for your evaluation and selection.
4. Prototype Fabrication & Comparative Laboratory Testing
Physical prototypes are manufactured based on the selected design. Comparative tests are conducted under identical operating conditions, and a complete test report covering the original and optimized samples will be delivered.
5. Design Finalization & Update of Mass-Production Documentation
Once the optimal solution is confirmed, we complete drawing revision, tolerance adjustment and surface process specifications. A full set of form
Our Service Model for Thermal Product Optimization
Therefore, our latest product optimization work aims to improve the long-term operational stability of customers’ thermal management products while achieving reasonable cost control. We take into full consideration thermal performance, structural reliability and manufacturability to reduce frequent product failures and help customers cut overall production costs.
If you have new projects requiring design services or existing products to be optimized, a dedicated project engineer will be assigned to support you. We can provide services ranging from solution design to product supply. We are able to deliver original design proposals and drawings, which you may use for sampling at any manufacturer. Naturally, we hope to undertake the subsequent production. After all, we are an enterprise integrating R&D and manufacturing, and manufacturing constitutes our core business..
