Micro-channel liquid cooling plate based on disordered ball filler and manufacturing method of micro-channel liquid cooling plate

Abstract

The microchannel liquid cooling plate comprises a plate body with an internal cavity, a plurality of regularly arranged blade teeth are arranged in the internal cavity of the plate body, and a plurality of metal balls are filled in gaps between the adjacent blade teeth. The metal balls and the blade teeth are connected in a metallurgical bonding mode and form a disordered micro-channel network in the gaps. The design is reasonable and ingenious, on the basis of form relieved tooth blade teeth, disorderly-arranged metal ball filler is introduced and combined with the form relieved tooth blade teeth, a high-specific-surface-area and strong-disturbance three-dimensional random micro-channel network is constructed, and therefore the heat exchange efficiency is remarkably improved, meanwhile, the process is kept relatively simple, and the cost is controllable.

Description

Technical Field

[0001] This application relates to the field of heat dissipation technology for electronic devices, and in particular to a microchannel liquid cooling plate based on disordered ball packing and its manufacturing method. Background Technology

[0002] With the continuous increase in the power density of electronic devices, liquid cooling technology has become the mainstream solution due to its advantages such as high efficiency and quiet operation. Tooth cutting, a mature metal forming technology, can cut neatly arranged, high aspect ratio thin-walled toothed blades from a substrate in a single process, forming regular flow channels. It is a common method for manufacturing liquid cooling plates. However, traditional toothed liquid cooling plates have regular flow channel shapes and smooth surfaces, resulting in limited disturbance to the coolant and a relatively thick heat transfer boundary layer, which restricts further improvement in heat dissipation performance.

[0003] To enhance the perturbation, existing technologies have proposed various solutions, such as adding complex turbulent structures within the flow channel, or directly forming structures with complex three-dimensional microchannels using metal additive manufacturing technology. However, the former significantly increases process complexity and cost, such as secondary processing of turbulence columns; the latter suffers from high manufacturing costs, high printed surface roughness, limited minimum feature size, difficulty in stably manufacturing channels with diameters less than 800 μm and clean interiors, and potentially inferior material properties compared to forged or cast parts.

[0004] Therefore, there is an urgent need to develop a microchannel liquid cooling plate and its manufacturing method that combines high heat exchange efficiency, excellent reliability, low manufacturing cost, and good process feasibility. Summary of the Invention

[0005] In view of at least one of the above technical problems, this application provides a microchannel liquid cooling plate based on disordered ball packing.

[0006] The present invention also provides a method for manufacturing the microchannel liquid cooling plate based on disordered spherical packing.

[0007] An embodiment of the first aspect of this application provides a microchannel liquid cooling plate based on disordered ball packing, comprising a plate body having an internal cavity, wherein a plurality of regularly arranged blade teeth are provided in the internal cavity of the plate body, and a plurality of metal balls are filled in the gaps between adjacent blade teeth, wherein the metal balls and blade teeth are connected by a metallurgical bonding method and form a disordered microchannel network in the gaps.

[0008] As a further improvement of the present invention, the plate body is provided with an inlet and an outlet that communicate with the internal cavity, and the internal cavity is filled with coolant.

[0009] As a further improvement of the present invention, the diameter of the metal ball is between 50 μm and 500 μm.

[0010] As a further improvement of the present invention, the diameter of the metal ball is 100 μm.

[0011] As a further improvement of the present invention, the metal ball and the blade tooth are made of the same material, namely aluminum, aluminum alloy, copper or copper alloy.

[0012] As a further improvement of the present invention, the metal balls are randomly stacked within the gap.

[0013] As a further improvement of the present invention, the plate body includes a plate body, the blade teeth are provided in the internal cavity of the plate body, and a cover plate is sealed to the top of the internal cavity, and the liquid inlet and liquid outlet are provided on the cover plate.

[0014] As a further improvement of the present invention, the leaf teeth are formed in the internal cavity of the plate by a tooth-shaving process.

[0015] A method for manufacturing the aforementioned microchannel liquid cooling plate based on disordered spherical packing includes the following steps: S1: Provide a plate with an internal cavity; S2: Multiple regularly arranged leaf teeth are machined in the cavity of the plate body using a tooth-shaving process; S3: Fill the gaps between adjacent leaf teeth with multiple metal balls; S4: The metal spheres and the blade teeth are metallurgically bonded together by brazing or sintering processes to form a disordered microchannel network.

[0016] As a further improvement of the present invention, in step S3, metal balls are filled by free fall filling or vibration filling. In step S4, the sintering process is liquid phase sintering.

[0017] The embodiments of this application have the following technical effects: The present invention is reasonably and ingeniously designed. Based on the toothed blade, by introducing and combining randomly arranged metal ball packings, a three-dimensional random microchannel network with high specific surface area and strong disturbance is constructed, thereby significantly improving the heat exchange efficiency while maintaining a relatively simple process and controllable cost.

[0018] Excellent heat transfer performance: The randomly arranged metal spheres form a large number of random microchannels and bluff bodies within the flow channel, which effectively disrupts the laminar boundary layer of the coolant, generating strong turbulence and secondary flow, greatly enhancing the convective heat transfer coefficient between the fluid and the solid. At the same time, the metal spheres themselves provide a huge additional heat transfer surface area.

[0019] It boasts excellent process compatibility and controllable costs: the core structure is based on mature tooth-shoveling technology, with only the addition of ball-filling and bonding steps. Compared to full 3D printing solutions, this invention offers significant advantages in material costs, equipment investment, and manufacturing efficiency.

[0020] Reliable structure: Through metallurgical bonding, a strong connection is formed between the metal ball and the blade tooth, as well as between the metal balls themselves, avoiding the risk of particles falling off under fluid impact and ensuring long-term reliability.

[0021] Flexible design: By changing the diameter, material, packing density, or geometric parameters of the blades, the porosity, specific surface area, and flow resistance of the microchannel network can be flexibly adjusted to meet different heat dissipation and pressure drop requirements.

[0022] The present invention will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0023] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0024] Figure 1 This is a three-dimensional structural schematic diagram of the present invention; Figure 2 This is a schematic diagram of the structure of the plate and blade teeth in this invention; Figure 3 yes Figure 2 Enlarged schematic diagram of part A in the diagram. Detailed Implementation

[0025] To make the above-mentioned objectives, features, and advantages of this application more apparent and understandable, the specific embodiments of this application are described in detail below with reference to the accompanying drawings. Many specific details are set forth in the following description to provide a thorough understanding of this application. However, this application can be implemented in many other ways different from those described herein, and those skilled in the art can make similar modifications without departing from the spirit of this application. Therefore, this application is not limited to the specific embodiments disclosed below.

[0026] In the description of this application, it should be understood that the terms "upper", "lower", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this application.

[0027] In the description of this application, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include at least one of that feature. In the description of this application, "multiple" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0028] In the embodiments of this application, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. For those skilled in the art, the specific meaning of the above terms in the embodiments of this invention can be understood according to the specific circumstances.

[0029] like Figures 1 to 3 As shown, an embodiment of this application provides a microchannel liquid cooling plate based on disordered ball packing, including a plate body 1 with an internal cavity. The internal cavity of the plate body 1 is provided with a plurality of regularly arranged blade teeth 2. A plurality of metal balls 3 are filled in the gaps 13 between adjacent blade teeth 2. The metal balls 3 are connected to the blade teeth 2 by a metallurgical bonding method and form a disordered microchannel network in the gaps 13.

[0030] The plate body 1 is provided with a liquid inlet 4 and a liquid outlet 5 that communicate with the internal cavity, and the internal cavity is filled with coolant.

[0031] The diameter of the metal sphere 3 is between 50 μm and 500 μm.

[0032] The diameter of the metal sphere 3 is 100 μm.

[0033] The metal ball 3 and the blade tooth 2 are made of the same material, namely aluminum, aluminum alloy, copper or copper alloy.

[0034] The metal balls 3 are randomly stacked within the gap 13.

[0035] The plate body 1 includes a plate body 11, the blade teeth 2 are provided in the internal cavity of the plate body 11, and a cover plate 12 is sealed to the top of the internal cavity. The liquid inlet 4 and the liquid outlet 5 are provided on the cover plate 12.

[0036] The leaf teeth 2 are formed in the internal cavity of the plate 11 by a tooth-shaving process.

[0037] A method for manufacturing the aforementioned microchannel liquid cooling plate based on disordered spherical packing includes the following steps: S1: Provide a plate 11 with an internal cavity; S2: Multiple regularly arranged leaf teeth 2 are machined in the cavity of the plate 11 by a tooth-shaving process; S3: Fill the gap 13 between adjacent leaf teeth 2 with multiple metal balls 3; S4: The metal spheres 3 and the blade teeth 2 are metallurgically bonded together by brazing or sintering processes to form a disordered microchannel network.

[0038] As a further improvement of the present invention, in step S3, the metal ball 3 is filled by free fall filling or vibration filling. In step S4, the sintering process is liquid phase sintering.

[0039] Specifically, firstly, an aluminum alloy plate with a thickness of 10mm is provided as the plate body 11. On the upper surface of the plate body 11, an array of parallel blade teeth 2 with a height of 8mm, a thickness of 0.3mm, and a spacing of 1mm is machined using a high-precision tooth-shaving machine to form a regular flow channel.

[0040] Then, spherical aluminum powder with a diameter of approximately 100 μm was selected as metal sphere 3, and the purity of the spherical aluminum powder was 99.5%. The aluminum powder was uniformly vibrated and filled into all the gaps 13 between the blade teeth 2 through a precision sieve and a vibrating table until it was filled and reached a natural close-packed state.

[0041] Next, a layer of low-melting-point aluminum-silicon alloy brazing foil (not shown) is covered on the surface of the plate 11 filled with aluminum powder, and then an aluminum alloy cover plate 12 with machined flow channels is placed on top. The cover plate 12 has a liquid inlet 4 and a liquid outlet 5 pre-drilled on it.

[0042] Finally, the entire assembly is placed in a vacuum brazing furnace. Under vacuum, the temperature is raised to approximately 600°C, slightly above the melting point of the brazing filler metal, and held for a period of time. After melting, the brazing filler metal penetrates through capillary action into the spaces between aluminum powder particles and the contact points between the particles and the blade teeth 2, forming a strong metallurgical bond upon cooling. Thus, the blade teeth 2 and the metal spheres 3 are combined into a single unit, creating numerous interconnected but randomly oriented microchannels within it.

[0043] Tests showed that, under the same pump power conditions, the convective heat transfer coefficient of this liquid cooling plate was increased by approximately 65% ​​compared to a pure toothed liquid cooling plate without aluminum powder filling.

[0044] Alternatively, after filling with copper powder spheres approximately 200 μm in diameter, no additional solder can be added. A sintering process can be directly employed: the assembly without the cover plate 12 is placed in a reducing atmosphere sintering furnace, such as a hydrogen-nitrogen mixture, and liquid-phase sintering is performed at a temperature below the melting point of copper, such as 900°C. By controlling the sintering temperature and time, the copper powder particles are allowed to grow and fuse in contact with the neck, while also achieving a strong bond with the copper blade teeth 2. After sintering, the cover plate 12 is then welded on.

[0045] This solution is suitable for applications requiring extremely high thermal conductivity.

[0046] Third, the blade teeth 2 can be set to a height of 5mm and a spacing of 2mm. Small aluminum alloy spheres with a diameter of approximately 400μm are used as filler. This design allows for a wider flow channel and larger sphere diameter, making it suitable for applications with higher flow rates and greater sensitivity to flow pressure drop.

[0047] The invention is reasonably and ingeniously designed. Based on the shovel blade teeth 2, it introduces and combines randomly arranged metal ball packing 3 with the shovel blade teeth to construct a three-dimensional random microchannel network with high specific surface area and strong disturbance, thereby significantly improving heat exchange efficiency while maintaining a relatively simple process and controllable cost.

[0048] Excellent heat transfer performance: The randomly arranged metal spheres 3 form a large number of random microchannels and bluff bodies within the flow channel, which can effectively disrupt the laminar boundary layer of the coolant, generating strong turbulence and secondary flow, greatly enhancing the convective heat transfer coefficient between the fluid and the solid. At the same time, the metal spheres 3 themselves provide a huge additional heat transfer surface area.

[0049] It boasts excellent process compatibility and controllable costs: the core structure is based on mature tooth-shoveling technology, with only the addition of ball-filling and bonding steps. Compared to full 3D printing solutions, this invention offers significant advantages in material costs, equipment investment, and manufacturing efficiency.

[0050] Reliable structure: Through metallurgical bonding, a strong connection is formed between the metal ball 3 and the blade tooth 2, avoiding the risk of particles falling off under fluid impact and ensuring long-term reliability.

[0051] Flexible design: By changing the diameter, material, filling density of the metal ball 3 or the geometric parameters of the blade teeth 2, the porosity, specific surface area and flow resistance of the microchannel network can be flexibly adjusted to meet different heat dissipation and pressure drop requirements.

[0052] The above description is merely a preferred embodiment of this application and does not constitute any limitation on this application. Any person skilled in the art can make many possible variations and modifications to the technical solution of this application, or modify it into equivalent embodiments, without departing from the scope of the technical solution of this application. Therefore, all equivalent changes made based on the shape, structure, and principle of this application without departing from the content of the technical solution of this application should be covered within the protection scope of this application.

Claims

1. A microchannel liquid cooling plate based on disordered spherical packing, characterized in that, The plate body includes a plate body with an internal cavity. The internal cavity of the plate body is provided with a number of regularly arranged leaf teeth. The gaps between adjacent leaf teeth are filled with a number of metal balls. The metal balls and leaf teeth are connected by a metallurgical bonding method and form a disordered microchannel network in the gaps.

2. The microchannel liquid cooling plate based on disordered spherical packing according to claim 1, characterized in that, The plate body is provided with an inlet and an outlet that communicate with the internal cavity, and the internal cavity is filled with coolant.

3. The microchannel liquid cooling plate based on disordered spherical packing according to claim 1 or 2, characterized in that, The diameter of the metal sphere is between 50 μm and 500 μm.

4. The microchannel liquid cooling plate based on disordered spherical packing according to claim 3, characterized in that, The diameter of the metal sphere is 100 μm.

5. The microchannel liquid cooling plate based on disordered spherical packing according to claim 1 or 2, characterized in that, The metal ball and the blade tooth are made of the same material, namely aluminum, aluminum alloy, copper or copper alloy.

6. The microchannel liquid cooling plate based on disordered spherical packing according to claim 1 or 2, characterized in that, The metal balls are randomly stacked within the gap.

7. The microchannel liquid cooling plate based on disordered spherical packing according to claim 2, characterized in that, The plate body includes a plate body, and the blade teeth are provided in the internal cavity of the plate body. A cover plate is sealed to the top of the internal cavity, and the liquid inlet and liquid outlet are provided on the cover plate.

8. The microchannel liquid cooling plate based on disordered spherical packing according to claim 7, characterized in that, The leaf teeth are formed in the internal cavity of the plate by a tooth-scraping process.

9. A method for manufacturing a microchannel liquid cooling plate based on disordered spherical packing as described in any one of claims 1 to 8, characterized in that, It includes the following steps: S1: Provide a plate with an internal cavity; S2: Multiple regularly arranged leaf teeth are machined in the cavity of the plate body using a tooth-shaving process; S3: Fill the gaps between adjacent leaf teeth with multiple metal balls; S4: The metal spheres and the blade teeth are metallurgically bonded together by brazing or sintering processes to form a disordered microchannel network.

10. The manufacturing method according to claim 9, characterized in that, In step S3, metal spheres are filled by free fall filling or vibration filling. In step S4, the sintering process is liquid phase sintering.

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