
CAD
Caddock Electronics, 2002
K
DOC
Calculation Examples
Using Equation 1 and data from Table 1, the allow-
able power can be determined for given ambient con-
ditions. Assuming a maximum ambient air tempera-
ture of 50
°
C with the part mounted using thermal
grease on an aluminum chassis, the allowable power
can be calculated from Equation 1 as follows:
P
D
=
P
D
=
P
D
=
P
D
= 31.25 watts
The same part, mounted on a water cooled heat sink
providing a constant 50
°
C reference temperature, will
dissipate more than twice this amount of power.
P
D
=
P
D
= 62.5 watts
Surge and Pulse Ratings
Surge or pulse voltages can be a factor in design reli-
ability. The following guidelines should be followed.
1. Do not exceed 750 volts peak.
2. Use the following guidelines for maximum pulse en-
ergy of a single pulse.
Pulse Width
10
μ
sec
100
μ
sec
1 msec
10 msec
100 msec
Energy (1 J = 1 Watt second)
0.07 J
0.25 J
0.90 J
3.5 J
15 J
3. Accumulated pulse energy delivered in each sec-
ond should not exceed allowable average power. De-
rate the pulse energy using the Derating Curve (Fig-
ure 1) based on estimated case temperature.
4. Above 100 msec to 5 seconds, the overload rating
is 1.5 times the allowable power of the resistor in the
application.
Table 1
Typical Thermal Resistance of Various
Materials Used for High-Power Designs with
Caddock MP9100 Resistors
Applications Engineering Note: AEN-0102
Page 2 of 2 - Rev. A
A copy of this Application Note can be obtained at www.caddock.com
Resistor Type
RJC
°
C/W)
Caddock MP9100 (junction to case)
Interface Material (thickness)
RCS
°
C/W)
Solder (0.010
”
)
Epoxy (0.010
”
)
Filled Epoxy (0.010
”
)
Thermal Grease (0.003
”
)
Q-Pad II (0.006
”
)
SIL-PAD 400 (0.007
”
)
SIL-PAD 2000 (0.015
”
)
Thermal Clad
dielectric (0.003
”
)
FR-4 / G-10 printed-circuit
board (0.063
”
)
Aluminum (0.063
”
)
Copper (0.063
”
)
Steel (0.063
”
)
96% Alumina (0.030
”
)
Aluminum Nitride (0.030
”
)
Beryllia (0.030
”
)
Typical Mounting Surfaces
to Ambient Air
SA
°
C/W)
7" X 5" X 2" 0.040"
Aluminum chassis
Small Finned Sheet Aluminum
heat sink (convection)
Small Finned Sheet Aluminum
heat sink (200 LFM Airflow)
4.5" X 3" X 3" Mult-Finned
Extruded Aluminum (convection)
4.5" X 3" X 3" Mult-Finned
Extruded Aluminum (200 LFM)
1.5
0.1
10
2.5
0.5 to 2
0.9
3.1
1.7
0.4
20 to 65
0.1
0.06
0.5
0.36
0.1
0.05
2
20
10
1.5
0.8
(R
JC
+ R
CS
+ R
SA
)
T
J
- T
A
(1.5
°
C/W + 0.5
°
C/W + 2
°
C/W)
175
°
C
- 50
°
C
4
°
C/W
125
°
C
(1.5
°
C/W + 0.5
°
C/W)
175
°
C
- 50
°
C
Mounting Configurations
Mounting pressure, surface cleanliness, surface flat-
ness and surface finish are just a few of the variables
which can have considerable effect on temperature
rise and power dissipation. Caddock recommends an
ideal spring mounting force of 4 to 15 pounds, or a
typical mounting screw torque of 6 to 8 in - lbs which
should provide 150 to 300 pounds of force. If a screw
is used, Caddock recommends the use of a good ther-
mal grease in conjunction with a #6 Belleville washer
compressed to 50% of its normal height. These wash-
ers (p/n 04CSB52200F004) are available from Ari-
zona Hydrogen, phone number 602-275-4126.