Once again the heat radiating properties of copper provides a solution to a high-tech overheating issue with computer components. With computers and especially video cards, fast isn’t often fast enough, and the ever present quest for more speed usually leads to an upgrade of existing components, which sometimes creates compatibility and heat issues, especially in the confined spaces of a laptop. 
When Dell owners upgraded the video card in an Inspiron 8500 with the Mobility Radeon 9600 Pro Turbo, over heating became a serious issue. Although the Inspiron BIOS recognizes the Radeon 9600 correctly and it does work in the 8500, there is no BIOS support for the overheating issue.
During operation, users discovered the BIOS shut-off temperature is set low enough that the heat generated by the upgraded video card will cause the notebook to shut down. Thanks to Dell Community Member MadMax for supplying the pictures and the instructions that solves this problem. They key to the solution is using a small piece of copper plate that measures 3cm x 3cm x 1.5mm thick. Other items required include a heat sink compound such as Arctic Silver 5, rapid glue such as cyanacrylat from Loctite, soldering paste to clean the copper, Acetone and a small Philips head screwdriver.
It appears that the main issue that needs to be addressed is with the thermal pads that Dell uses for contact between the chip and heat sink on both GPU and CPU. These pads are quite thick and only marginally effective so you need to replace them with the 1.5 mm thick copper plate so the heat sink and GPU chip makes contact.
First, disassemble the video card until it looks like this photo. Then remove the pad that covers the die of the GPU. Clean the die with Acetone or Isopropyl alcohol that is over 99% pure. Apply the thermal compound to the copper plate, and then apply the rapid glue to each corner of the copper plate. Next, fix the copper plate to the metal making sure the side with the heat sink compound and glue is facing the metal. Apply some thermal compound on the die and screw the parts together making sure that you do not tighten the screws too much, which can crack if too much pressure is applied to the die. Remember, copper expands when it gets warm so you need to make sure there is enough room for expansion.
Install the card back into your notebook and you will note that the CPU operates at about 50°C while the GPU heats up to 75-80°C in 3D games, compared to the original 100°C.
For more detailed photos and instructions, use this link and note the English instructions are on the photos. MadMax instructions.
Copper, so many solutions for such a simple metal! Call 1-888-334-2177 for your copper solution.
