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Adding heatsink with electrical isolation

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Gyro:
Aside from agreeing with the others that the correct way to do it is to use a thermal pad between the TO220 package and the case...

Assuming that you did manage to achieve sufficient thermal coupling between the elements of your large area air-gap heat exchanger, how would you manage to ensure that the mechanical clearances were maintained well enough to achieve proper electrical isolation?

EEEnthusiast:
The electrical isolation is guaranteed by the precision in the assembly process only. The TO-220 package height above the PCB is fixed and so is the heat sink height. The other heat sink on the case is also fixed at a constant location by marking it.

BravoV:
Just make a suitable metal insert between the TO220 and the case,  use good thermal pad to insulate it electrically to the metal case, but thermally coupled thru the pad.

This has been done for many many decades, why you sound like you are trying to reinvent the wheel, but yet using non circle shaped wheel ?  :-//

EEEnthusiast:
My issue is with the case style. The case I am using is a aluminium extrusion with open ends on two sides. The PCB slides into the case from the sides. So there is no easy way for me to access the package once the PCB is inside.

MagicSmoker:

--- Quote from: EEEnthusiast on December 11, 2019, 02:30:00 pm ---My issue is with the case style. The case I am using is a aluminium extrusion with open ends on two sides. The PCB slides into the case from the sides. So there is no easy way for me to access the package once the PCB is inside.

--- End quote ---

Well, you've boxed yourself in pretty good, then <rimshot>!

You might be able to transfer enough heat from a board-mounted, but physically separate, heatsink to the aluminum enclosure by using a stirring fan - basically, a fan inside the box that blows the air around inside. This can be surprisingly effective, but you do need to have a relatively large enclosure surface area and it needs to made of aluminum, not steel and definitely not plastic.

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