Method for continuous extrusion of asymmetric copper microchannel profiles and die

Abstract

The present application belongs to the technical field of continuous extrusion plastic forming of non-ferrous metals, and particularly relates to a continuous extrusion regulation method and a die for an asymmetric copper micro-channel profile, comprising the following steps: S1, obtaining basic parameters; S2, selecting the sizes of left and right copper rods according to the feed ratio q and satisfying: S3, substituting the basic parameters into the following flow uniformity balance main formula to obtain the flow passage equivalent depth of the left and right split flow cavities and the average depth of the welding chamber: S4, setting the welding length L 焊合 and the welding chamber width W 焊合 , substituting into the following welding critical constraint formula to obtain the welding time t w : the k is the device feed coefficient of the extrusion wheel; S5, when t w satisfies t w ≥0.8, the verification is qualified and the die processing is completed, otherwise, the rotational speed of the left and right extrusion wheels or the die cavity setting parameters are adjusted and the step S2 is returned to recalculate until the standard is reached.

Description

Technical Field

[0001] This invention belongs to the field of continuous extrusion plastic forming technology of non-ferrous metals, specifically relating to a method and mold for continuous extrusion control of asymmetric copper microchannel profiles. Background Technology

[0002] Continuous extrusion (CONFORM) is currently the mainstream production method for copper microchannel heat dissipation profiles for optical modules, enabling continuous production of long profiles. However, in actual mass production, existing processes have the following unresolved core problems for asymmetric copper profiles with unequal wall thicknesses at the top and bottom and vertical extrusion, which are commonly used in optical modules:

[0003] Because the high-temperature fluidity of pure copper is much lower than that of aluminum alloy, the existing single-bar feeding process requires splitting the material flow from a single copper bar into two asymmetrical streams, then rotating it 90 degrees for vertical extrusion. This results in a long splitting path, numerous flow channel turns, and extremely high flow resistance. Copper material easily forms flow dead zones in the flow channel, leading to either insufficient material supply on the thick-walled side to fill the microchannels, or uncontrolled flow velocity on the thin-walled side causing the profile to crack. It is impossible to stably control the ratio of the upper and lower material streams, resulting in extremely poor mass production stability.

[0004] Meanwhile, the asymmetrical structure of vertical discharge naturally requires more material to the thick-walled side and less material to the thin-walled side. Single-rod feeding can only rely on the complex diversion holes in the mold to adjust the flow rate. Either the flow rate is barely leveled, but the material flow repeatedly turns in the mold, resulting in insufficient welding stroke and pressure, leading to weld delamination and microchannel leakage; or the welding stroke is guaranteed, but the difference in flow rate between the upper and lower parts is amplified, resulting in profile bending and dimensional deviation. It is difficult to meet these two core indicators at the same time.

[0005] More importantly, the optical module industry has a demand for rapid iteration, high precision, and high reliability in mass production, but the existing process requires more than 8 trial runs, which seriously affects the requirements for rapid mass production and upgrading.

[0006] Therefore, overcoming the shortcomings of existing optical module copper microchannel heat dissipation profiles, such as the large number of trial moldings and uncontrollable performance, is a technical problem that urgently needs to be solved in this field.

[0007] It should be noted that the information disclosed in this background section is only for understanding the background technology of the present application concept, and therefore, the above description is not considered to constitute prior art information. Summary of the Invention

[0008] Addressing the core pain points of existing single-rod feeding processes, the core objective of this invention is to pioneer a system of independent left and right dual-rod feeding and vertical discharge, specifically targeting the poor fluidity of pure copper. This system utilizes two independently adjustable copper rods, one on the left and one on the right, feeding separately. These rods correspond to independent flow chambers on the left and right sides of the mold, directly matching the material flow requirements of profiles with varying wall thicknesses. This completely solves the problems of difficult flow distribution and numerous flow channel detours associated with single-rod feeding from the source of material feeding. Simultaneously, it achieves the dual goals of completely uniform flow in the upper and lower regions and satisfactory welding quality at the intermediate interface, significantly reducing the number of trial moldings and improving mass production yield.

[0009] This disclosure provides at least one method and mold for continuous extrusion control of asymmetric copper microchannel profiles.

[0010] In a first aspect, embodiments of this disclosure provide a method for controlling the continuous extrusion of asymmetric copper microchannel profiles, comprising the following steps: S1, Obtain basic parameters, including the total height H of the pre-prepared profile and the upper wall thickness d. 上 Lower wall thickness d 下 The total width W is calculated, and the feed ratio q and the cross-sectional area S of the upper wall region of the profile are obtained. 上 Cross-sectional area S of the lower wall region of the profile 下 ; q= ; S 上 = *W; S 下 = *W; S2, Select the dimensions of the left and right copper rods according to the feed ratio q and satisfy the following: q= ; The n 左 n 右 These are the rotational speeds of the left and right extrusion rollers, S. rod左 and S rod右 These are the cross-sectional areas of the left and right copper rods, respectively. S3, Substitute the basic parameters into the following master formula for uniform flow equilibrium, and obtain the equivalent depth of the flow channel and the average depth of the welding chamber for the left and right flow split cavities. : ; ; The H 流左 H 流右 The equivalent depths of the flow channels for the left and right split cavities are respectively, and T is... 左 T 右 The set temperatures for the left and right flow channels are respectively, where Q is the activation energy for plastic deformation of pure copper, and R is the ideal gas constant. S4, Set the welding length L 焊合 Width W of the welding chamber 焊合 Substituting into the following critical constraint formula for welding, we obtain the welding time t. w : ; k is the equipment feed coefficient of the extrusion wheel; S5, when t w Satisfy t w If the value is ≥0.8, the mold processing is completed and the verification is passed. If the value is not met, the rotation speed of the left and right extrusion rollers or the mold cavity setting parameters are adjusted and the process is returned to S2 to recalculate until the value is met.

[0011] In one optional embodiment, the left copper rod corresponds to the upper wall region, and the right copper rod corresponds to the lower wall region; and the upper wall thickness d 上 > Lower wall thickness d 下 .

[0012] In one optional implementation, in the master equation for uniform flow equilibrium, Q is 197000 J / mol and R is 8.314 J / (mol·K).

[0013] In one optional embodiment, the mold cavity setting temperature of the left split cavity is 30-50°C higher than the mold cavity setting temperature of the right split cavity; and / or, the preheating temperature of the left copper rod is 30-60°C higher than the preheating temperature of the right copper rod.

[0014] In one optional embodiment, the welding length L of the welding chamber 焊合 The value is 4 to 6 mm, and it is consistent in the left and right directions.

[0015] In one alternative embodiment, the welding chamber width W 焊合 It is 1-2 mm wider than the total width W of the pre-prepared profile.

[0016] Secondly, this disclosure also provides a die for continuous extrusion production of asymmetric copper microchannel profiles, comprising: an upper die and a lower die coaxially assembled; the upper die is provided with completely independent left and right flow-dividing cavities, corresponding to the feed inlets of left and right copper rods respectively; the outlets of the left and right flow-dividing cavities symmetrically converge into a welding chamber at the center of the die, and the downstream of the welding chamber is connected to a vertical discharge shaping working zone; the die calculates the equivalent flow channel depth H of the left and right flow-dividing cavities using the method described above. 流左 With H 流右 and average depth of the welding chamber .

[0017] Thirdly, this disclosure also provides a continuous extrusion production method for asymmetric copper microchannel profiles, comprising the following steps: billet pretreatment: peeling the surfaces of the left and right copper rods to remove oxide scale and oil stains, and preheating to 150-300°C to ensure stable friction coefficient; parameter control: preheating the die to 500-650°C, calculating and controlling the die parameters as described above, and performing welding and traction to produce the profile; shaping control: after the profile exits the die vertically, rapidly cooling the profile temperature to below 100°C using annular air cooling and water mist, and performing vertical correction to remove bending and twisting to obtain the asymmetric copper microchannel profile.

[0018] In one alternative embodiment, the outlet temperature of the welding chamber is 550–650°C.

[0019] In one optional embodiment, the rotational speed fluctuation of the left and right extrusion rollers does not exceed ±0.5 rpm, and the start and stop of the left and right extrusion rollers adopts ramp-type acceleration and deceleration, with acceleration and deceleration not exceeding 1 rpm / s.

[0020] The beneficial effects of this invention are as follows: This continuous extrusion control method and mold for asymmetric copper microchannel profiles establishes a master formula for uniform flow balance adapted to vertical discharge of left and right double rods. It incorporates four core variables—double rod size, rotation speed, flow channel design, and temperature control—into a quantitative system, locking the material flow balance between the left and right feeds in one step. Without the need for trial and error, the forming effect can be predicted during the mold design stage. At the same time, it is equipped with a critical constraint formula for welding, which is fully linked to the parameters of the master formula. It quantifies the matching relationship between welding stroke, welding time, and feed speed, and forcibly locks the critical conditions for pure copper welding. While ensuring uniform flow, it ensures good welding of the left and right material flows, without delamination or leakage defects.

[0021] Other features and advantages of the invention will be set forth in the following description, and will be apparent in part from the description, or may be learned by practicing the invention. The objects and other advantages of the invention are realized and obtained through the structures particularly pointed out in the description and the drawings.

[0022] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0023] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0024] Figure 1 A physical image of a copper microchannel profile for an 11-hole vertical output optical module with a wall thickness ratio of 2.15:1, provided for an embodiment of this disclosure; Figure 2 This disclosure provides a 1:1 equal wall thickness, 11-hole ultra-thin vertical discharge compact COB packaged optical module copper microchannel profile. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] As used herein, the phrases “in one embodiment,” “according to one embodiment,” “in some embodiments,” etc., generally refer to the fact that a particular feature, structure, or characteristic following the phrase can be included in at least one embodiment of this disclosure. Therefore, a particular feature, structure, or characteristic can be included in more than one embodiment of this disclosure, such that these phrases do not necessarily refer to the same embodiment. As used herein, the terms “example,” “exemplary,” etc., are used to “serve as an example, instance, or illustration.” Any implementation, aspect, or design described herein as “example” or “exemplary” is not necessarily to be construed as preferred or superior to other implementations, aspects, or designs. Rather, the use of the terms “example,” “exemplary,” etc., is intended to present concepts in a specific manner.

[0027] The following detailed description of some embodiments of the present invention is provided in conjunction with the accompanying drawings. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0028] This disclosure provides a method for controlling the continuous extrusion of asymmetric copper microchannel profiles, including the following steps: S1, Obtain basic parameters, including the total height H of the pre-prepared profile and the upper wall thickness d. 上 Lower wall thickness d 下 The total width W is calculated, and the feed ratio q and the cross-sectional area S of the upper wall region of the profile are obtained. 上 Cross-sectional area S of the lower wall region of the profile 下 ; q= ; S 上 = *W; S 下 = *W; S2, Select the dimensions of the left and right copper rods according to the feed ratio q and satisfy the following: q= ; The n 左 n 右 These represent the rotational speeds of the left and right extrusion rollers, in rpm and seconds, respectively. rod左 and S rod右 These are the cross-sectional areas of the left and right copper rods, respectively, in mm. 2 ; S3, Substitute the basic parameters into the following master formula for uniform flow equilibrium, and obtain the equivalent depth of the flow channel and the average depth of the welding chamber for the left and right flow split cavities. : ; ; The H 流左 H 流右 These are the equivalent depths of the flow channels in the left and right split cavities, respectively, in mm. The T... 左 T 右 The set temperatures for the left and right flow channels are respectively, in °C. Q is the activation energy for plastic deformation of pure copper, and R is the ideal gas constant. S4, Set the welding length L 焊合 Width W of the welding chamber 焊合 Substituting into the following critical constraint formula for welding, we obtain the welding time t. w : ; The k is the equipment feed coefficient of the extrusion wheel, which is related to the equipment model; The t w This refers to the effective welding time of copper material in the welding chamber. The critical welding value for continuous extrusion of pure copper is 0.8 seconds; only welding that does not fall below this critical value can achieve a strong weld. The L... 焊合 The effective welding length of the welding chamber; The average depth of the welding chamber is H. 流左 H 流右 The average value.

[0029] S5, when t w Satisfy t w If the value is ≥0.8, the mold processing is completed and the verification is passed. If the value is not met, the rotation speed of the left and right extrusion rollers or the mold cavity setting parameters are adjusted and the process is returned to S2 to recalculate until the value is met.

[0030] In some embodiments, specifically, the left copper rod corresponds to the upper wall region, and the right copper rod corresponds to the lower wall region; and the upper wall thickness d 上 > Lower wall thickness d 下 .

[0031] In some embodiments, specifically, in the master formula for uniform flow equilibrium, Q represents the activation energy of plastic deformation of pure copper, with a fixed value of 197,000 J / mol, and R represents the ideal gas constant, with a fixed value of 8.314 J / (mol·K).

[0032] In some embodiments, specifically, the mold cavity setting temperature of the left split cavity is 30-50°C higher than the mold cavity setting temperature of the right split cavity; and / or, the preheating temperature of the left copper rod is 30-60°C higher than the preheating temperature of the right copper rod.

[0033] In some embodiments, specifically, the welding length L of the welding chamber 焊合 The value is 4 to 6 mm, and it is consistent in the left and right directions.

[0034] In some embodiments, specifically, the welding chamber width W 焊合 It is 1-2 mm wider than the total width W of the pre-prepared profile.

[0035] This disclosure also provides a die for continuous extrusion production of asymmetric copper microchannel profiles, comprising: an upper die and a lower die coaxially assembled; the upper die is provided with completely independent left and right flow channels, corresponding to the feed inlets of left and right copper rods respectively; the outlets of the left and right flow channels symmetrically converge into a welding chamber at the center of the die, and the downstream of the welding chamber is connected to a vertical discharge shaping working zone; the die calculates the equivalent flow channel depth H of the left and right flow channels using the method described above. 流左 With H 流右 and average depth of the welding chamber .

[0036] Specifically, the material flow in the left diversion cavity corresponding to the upper wall area of ​​the profile and the material flow in the right diversion cavity corresponding to the lower wall area of ​​the profile are only an optional embodiment. They can also be matched in reverse according to the profile wall thickness. The two material flows only converge and weld in the welding chamber in the middle of the mold, and then are extruded and formed in the vertical direction. They are completely separated from the feeding end, without the need to forcibly split the material flow in the mold. There is no extra detour in the flow channel, which solves the diversion problem from the root.

[0037] Specifically, the dimensions of the two copper rods can be designed independently. In one optional embodiment, a larger diameter rod can be used for the copper rod on the thick-walled side to directly match the larger feeding requirements; a smaller diameter rod can be used for the copper rod on the thin-walled side to match the material ratio from the source of raw materials, greatly reducing the design difficulty of the mold flow channel. At the same time, the speed of the extrusion rollers corresponding to the two copper rods can also be adjusted independently. The speed of the two rods can be set to be the same or adjusted separately. In one optional embodiment, if the thick-walled side needs to be replenished, the speed of the corresponding rod is increased; if the flow rate on the thin-walled side is too fast, the speed of the corresponding rod is decreased. Without modifying the mold, the material flow ratio can be accurately corrected simply by adjusting the process parameters, making mass production adjustments extremely convenient.

[0038] This disclosure also provides a continuous extrusion production method for asymmetric copper microchannel profiles, comprising the following steps: billet pretreatment: peeling the surface of the left and right copper rods to remove oxide scale and oil stains, and preheating to 150-300°C to ensure stable friction coefficient; parameter control: preheating the die to 500-650°C, calculating and controlling the die parameters as described above, and performing welding and traction to produce the profile; shaping control: after the profile exits the die vertically, rapidly cooling the profile temperature to below 100°C using annular air cooling and water mist, and performing vertical correction to remove bending and twisting to obtain the asymmetric copper microchannel profile.

[0039] In some embodiments, specifically, the outlet temperature of the welding chamber is 550–650°C.

[0040] In some embodiments, specifically, the rotational speed fluctuation of the left and right extrusion rollers does not exceed ±0.5 rpm, and the start and stop of the left and right extrusion rollers adopts ramp-type acceleration and deceleration, with acceleration and deceleration not exceeding 1 rpm / s.

[0041] Example 1: A copper microchannel profile for an 11-hole vertical output optical module with a wall thickness ratio of 2.15:1. Product drawing parameters: Total profile height 6.84mm, upper wall (thin-walled side) thickness 0.82mm, lower wall (thick-walled side) thickness 1.76mm, upper and lower wall thickness ratio 2.15:1; upper wall area cross-sectional area S 上 =17.14mm 2 Cross-sectional area S of the lower wall region 下 =36.43mm 2 The total width of the profile is 20.9mm, and it is discharged vertically.

[0042] Equipment: A dual-wheel 400-type continuous extrusion press, with independent drive for both left and right wheels, and a feed coefficient k = 0.066.

[0043] Specifically, the parameter adjustment methods are as follows: Boundary conditions are set: the left flow divider corresponds to the thin-walled side of the upper wall, and the cavity temperature T is... 左=530℃; the right flow divider corresponds to the thick-walled side of the lower wall, mold cavity temperature T 右 =570℃; Welding length L 焊合 =5mm, welding chamber width W 焊合 =22mm; Substituting into the master formula for uniform flow equilibrium, the calculated feed ratio between the thick-walled and thin-walled sides needs to be 2.1:1. Therefore, a copper rod with a diameter of φ16mm (S) is ultimately selected for the left rod (thin-walled side). rod左 =201mm 2 ), Right rod (thick-walled side) copper rod diameter φ20mm (S rod右 =314mm 2 ); Set the left lever speed n 左 =7rpm, right lever speed n 右 =8rpm, the feed rate ratio perfectly matches the design requirements; Simultaneously calculate the flow channel depth: left split cavity flow channel depth H 流左 =4mm, right split cavity flow channel depth H 流右 =8.4mm, average depth of welding chamber =6.2mm; Substituting into the critical constraint formula for welding, the welding time t is calculated. w =1.0s, which meets the critical requirement of ≥0.8s, and the welding quality meets the standard.

[0044] Specifically, the production process is as follows: The mold is processed according to the calculated parameters, with independent left and right flow chambers and equal-stroke streamlined transition channels. The welding chamber dimensions are processed strictly according to the design values, and the mold core inlet end is 3.5mm ahead of the working zone. The mold is preheated to 530℃, the left and right flow chambers are independently temperature-controlled according to the set temperature, and the two copper rods are preheated to 180℃; The left and right extrusion rollers start synchronously at the set speed, and the traction speed of the vertical traction machine is synchronized with the total feed rate, with a synchronization accuracy of ±0.2%. After the profile is vertically demolded, it is rapidly cooled by annular air cooling, vertically straightened online, and cut to length.

[0045] Please see Figure 1 Specifically, the profile results obtained in Example 1 are as follows: The production was successful on the first trial run. The flow rate difference between the upper and lower areas of the profile was ≤1.8%. There were no bends, tears, or dimensional deviations in the vertical discharge. The wall thickness tolerance was stable at ±0.03mm. The welding strength reached 92% of the base material. There was no leakage after holding the 10MPa water pressure for 30 minutes. After continuous production of 5000 meters, the yield rate was 98.7%, which fully meets the requirements for mass production.

[0046] Example 2: A copper microchannel profile for 800G optical modules with a 1.5:1 wall thickness ratio, 18 holes, and high density, vertical output. Product drawing parameters: Total profile height 5.2mm, upper wall (thin-wall side) thickness 0.7mm, lower wall (thick-wall side) thickness 1.05mm, upper and lower wall thickness ratio 1.5:1; upper wall area cross-sectional area S 上 =12.6mm 2 Cross-sectional area S of the lower wall region 下 =18.9mm 2 The profile has a total width of 18.2mm and contains 18 φ0.45mm microchannels for vertical discharge.

[0047] Equipment: A dual-wheel 300-type continuous extrusion press with independent drive for both left and right wheels. The feed coefficient k = 0.072.

[0048] Specifically, the parameter adjustment methods are as follows: Boundary conditions are set: the left flow divider corresponds to the thin-walled side of the upper wall, and the cavity temperature T is... 左 =520℃; the right flow divider corresponds to the thick-walled side of the lower wall, mold cavity temperature T 右 =560℃; Welding length L 焊合 =4.5mm, welding chamber width W 焊合 =19.5mm; Substituting into the master formula for uniform flow equilibrium, the calculated feed ratio between the thick-walled and thin-walled sides needs to be 1.52:1. Therefore, a copper rod with a diameter of φ14mm (S) is ultimately selected for the left rod (thin-walled side). rod左 =153.9mm 2 The right-hand (thick-walled side) copper rod has a diameter of φ17mm (S). rod右 =226.9mm 2 ); Set the left lever speed n 左 =8rpm, right lever speed n 右 =8.3rpm, the feed rate ratio perfectly matches the design requirements; Simultaneously calculate the flow channel depth: left split cavity flow channel depth H 流左 =3.6mm, right split cavity flow channel depth H 流右 =5.4mm, average depth of weld chamber =4.5mm; Substituting into the critical constraint formula for welding, the welding time t is calculated. w =0.92s, which meets the critical requirement of ≥0.8s, and the welding quality meets the standard.

[0049] Specifically, the production process is as follows: The mold is processed according to the calculated parameters, with independent left and right flow chambers and equal-stroke streamlined transition channels. The welding chamber dimensions are strictly processed according to the design values, and the mold core inlet end is 3mm ahead of the working zone. The mold is preheated to 525℃, the left and right flow chambers are independently temperature-controlled according to the set temperature, and the two copper rods are preheated to 180℃; The left and right extrusion rollers start synchronously at the set speed, and the traction speed of the vertical traction machine is synchronized with the total feed rate, with a synchronization accuracy of ±0.25%. After the profile is vertically demolded, it is rapidly cooled by annular air cooling, vertically straightened online, and cut to length.

[0050] Specifically, the profile results obtained in Example 2 are as follows: The production was successful on the first trial run. The flow rate difference between the upper and lower areas of the profile was ≤1.6%. There were no bends, tears, or dimensional deviations in the vertical discharge. The wall thickness tolerance was stable at ±0.025mm. The welding strength reached 91% of the base material. There was no leakage after holding the 12MPa water pressure for 30 minutes. 3200 meters were produced continuously with a yield rate of 98.5%, which fully meets the mass production requirements of 800G high-density optical modules.

[0051] Example 3: A copper microchannel profile for a high-power optical module with a 3.2:1 wall thickness ratio, an 8-hole large cross-section, and vertical discharge capacity of 1.6T. Product drawing parameters: Total profile height 8.6mm, upper wall (thin-walled side) thickness 0.65mm, lower wall (thick-walled side) thickness 2.08mm, upper and lower wall thickness ratio 3.2:1; upper wall area cross-sectional area S 上 =14.2mm 2 Cross-sectional area S of the lower wall region 下 =45.44mm 2 The profile has a total width of 24.5mm and contains 8 microchannels with a large diameter of φ1.2mm for vertical discharge.

[0052] Equipment: A dual-wheel 400-type continuous extrusion press, with independent drive for both left and right wheels, and a feed coefficient k = 0.066.

[0053] Specifically, the parameter adjustment methods are as follows: Boundary conditions are set: the left flow divider corresponds to the thin-walled side of the upper wall, and the cavity temperature T is... 左 =530℃; the right flow divider corresponds to the thick-walled side of the lower wall, mold cavity temperature T 右 =580℃; Welding length L 焊合 =6mm, welding chamber width W 焊合 =26mm; Substituting into the master formula for uniform flow equilibrium, the calculated feed ratio between the thick-walled and thin-walled sides needs to be 3.23:1. Therefore, a copper rod with a diameter of φ16mm (S) is ultimately selected for the left rod (thin-walled side). rod左 =201mm 2 The right-hand (thick-walled side) copper rod has a diameter of φ25mm (S). rod右 =490.6mm 2); Set the left lever speed n 左 =6rpm, right lever speed n 右 =7.9rpm, the feed rate ratio perfectly matches the design requirements; Simultaneously calculate the flow channel depth: left split cavity flow channel depth H 流左 =3.8mm, right split cavity flow channel depth H 流右 =12.2mm, average depth of weld chamber =8mm; Substituting into the critical constraint formula for welding, the welding time t is calculated. w =1.08s, which meets the critical requirement of ≥0.8s, and the welding quality meets the standard.

[0054] Specifically, the production process is as follows: The mold is processed according to the calculated parameters, with independent left and right flow chambers and equal-stroke streamlined transition channels. The welding chamber dimensions are strictly processed according to the design values, and the mold core inlet end is 4mm ahead of the working zone. The entire mold is preheated to 550℃, the left and right flow chambers are independently temperature-controlled according to the set temperature, and the two copper rods are preheated to 200℃; The left and right extrusion rollers start synchronously at the set speed, and the traction speed of the vertical traction machine is synchronized with the total feed rate, with a synchronization accuracy of ±0.2%. After the profile is vertically demolded, it is rapidly cooled by annular air cooling, vertically straightened online, and cut to length.

[0055] Specifically, the profile results obtained in Example 3 are as follows: The production was successful after only two trial runs. The flow rate difference between the upper and lower regions of the profile was ≤1.9%. There were no bends, tears, or dimensional deviations in the vertical discharge. The wall thickness tolerance was stable at ±0.03mm. The welding strength reached 90% of the base material. There was no leakage after holding the 10MPa water pressure for 30 minutes. 4500 meters were produced continuously with a yield rate of 98.2%, which fully meets the mass production requirements of 1.6T high-power optical modules.

[0056] Example 4: A 1:1 equal wall thickness, 11-hole ultra-thin vertically ejected compact COB packaged optical module copper microchannel profile Product drawing parameters: Total profile height 4.5mm, upper wall (thin-wall side) thickness 0.55mm, lower wall (thick-wall side) thickness 0.55mm, upper and lower wall thickness ratio 1:1; upper wall area cross-sectional area S 上 =9.9mm 2 Cross-sectional area S of the lower wall region 下 =9.9mm 2 The profile has a total width of 16.8mm and contains 11 ultra-thin wall microchannels with a diameter of 0.35mm, allowing for vertical material discharge.

[0057] Equipment: A dual-wheel 300-type continuous extrusion press with independent drive for both left and right wheels. The feed coefficient k = 0.072.

[0058] Specifically, the parameter adjustment methods are as follows: Boundary conditions are set: the left flow divider corresponds to the thin-walled side of the upper wall, and the cavity temperature T is... 左 =540℃; the right flow divider corresponds to the thick-walled side of the lower wall, mold cavity temperature T 右 =540℃; Welding length L 焊合 =4mm, welding chamber width W 焊合 =18mm; Substituting into the master formula for uniform flow equilibrium, it is calculated that the feed ratio between the thick-walled side and the thin-walled side must be 1:1. Therefore, a copper rod with a diameter of φ15mm (S) is ultimately selected for the left rod (thin-walled side). rod左 =176.7mm 2 The right-hand (thick-walled side) copper rod has a diameter of φ15mm (S). rod右 =176.7mm 2 ); Set the left lever speed n 左 =8.5rpm, right lever speed n 右 =8.5rpm, the feed rate ratio perfectly matches the design requirements; Simultaneously calculate the flow channel depth: left split cavity flow channel depth H 流左 =4.2mm, right split cavity flow channel depth H 流右 =4.2mm, average depth of welding chamber =4.2mm; Substituting into the critical constraint formula for welding, the welding time t is calculated. w =0.87s, which meets the critical requirement of ≥0.8s, and the welding quality meets the standard.

[0059] Specifically, the production process is as follows: The mold is processed according to the calculated parameters, with independent left and right flow chambers and equal-stroke streamlined transition channels. The welding chamber dimensions are processed strictly according to the design values, and the mold core inlet end is 3.5mm ahead of the working zone. The entire mold is preheated to 540℃, the left and right flow chambers are independently temperature-controlled according to the set temperature, and the two copper rods are preheated to 160℃; The left and right extrusion rollers start synchronously at the set speed, and the traction speed of the vertical traction machine is synchronized with the total feed rate, with a synchronization accuracy of ±0.15%. After the profile is vertically demolded, it is rapidly cooled by annular air cooling, vertically straightened online, and cut to length.

[0060] Please see Figure 2 Specifically, the profile results obtained in Example 4 are as follows: The production was successful on the first trial run. The flow rate difference between the upper and lower regions of the profile was ≤0.9%. There were no bends, tears, or dimensional deviations in the vertical discharge. The wall thickness tolerance was stable at ±0.02mm. The welding strength reached 93% of the base material. There was no leakage after holding the 15MPa water pressure for 30 minutes. 2800 meters were produced continuously with a yield rate of 99.1%, which fully meets the mass production requirements of ultra-thin wall microchannel profiles with symmetrical wall thickness.

[0061] As can be seen from Examples 1-4, the control method provided by the present invention comprehensively covers the mainstream application scenarios of the optical module industry. The wall thickness ratio and the number of microchannel holes have a wide coverage and are compatible with optical modules of 100G to 1.6T full rate. It includes all types of profiles such as asymmetric / symmetric structures, ultra-thin / large wall thickness, and high density / large aperture, which fully verify the universality, stability and mass production capability of the present invention, and fully meet the production needs of the optical module industry for rapid iteration, multiple specifications and high precision.

[0062] In summary, this method and mold for continuous extrusion control of asymmetric copper microchannel profiles establishes a master formula for uniform flow balance adapted to vertical discharge from the left and right dual rods. It incorporates four core variables—dual rod dimensions, rotational speed, flow channel design, and temperature control—into a quantitative system, locking in the material flow balance between the left and right feeds in one step. No trial and error is required; the forming effect can be predicted during the mold design stage. Simultaneously, a critical constraint formula for welding is provided, fully linked to the parameters of the master formula. This quantifies the matching relationship between welding stroke, welding time, and feed rate, forcibly locking in the critical conditions for pure copper welding. While ensuring uniform flow, it also ensures good welding of the left and right material flows, without delamination or leakage defects.

[0063] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A method for controlling the continuous extrusion of asymmetric copper microchannel profiles, characterized in that, Includes the following steps: S1, Obtain basic parameters, including the total height H of the pre-prepared profile and the upper wall thickness d. 上 Lower wall thickness d 下 The total width W is calculated, and the feed ratio q and the cross-sectional area S of the upper wall region of the profile are obtained. 上 Cross-sectional area S of the lower wall region of the profile 下 ; q= ； S 上 = *W; S 下 = *W; S2, Select the dimensions of the left and right copper rods according to the feed ratio q and satisfy the following: q= ； The n 左 n 右 These are the rotational speeds of the left and right extrusion rollers, S. rod左 and S rod右 These are the cross-sectional areas of the left and right copper rods, respectively; S3, Substitute the basic parameters into the following flow uniformity equilibrium master formula to obtain the equivalent depth of the flow channel and the average depth of the welding chamber for the left and right flow split cavities. : ； ； The H 流左 H 流右 The equivalent depths of the flow channels for the left and right split cavities are respectively, and T is... 左 T 右 The set temperatures for the left and right flow channels are respectively, Q is the activation energy for plastic deformation of pure copper, Q is 197000 J / mol, and R is the ideal gas constant; S4, Set the welding length L 焊合 Width W of the welding chamber 焊合 Substituting into the following critical constraint formula for welding, we obtain the welding time t. w : ； k is the equipment feed coefficient of the extrusion wheel; S5, when t w Satisfy t w If the value is ≥0.8, the mold processing is completed and the verification is passed. If the value is not met, the rotation speed of the left and right extrusion rollers or the mold cavity setting parameters are adjusted and the process is returned to S2 to recalculate until the value is met. The left copper rod corresponds to the upper wall area, and the right copper rod corresponds to the lower wall area; And the thickness of the upper wall d 上 > Lower wall thickness d 下 ; The set temperature of the mold cavity in the left split cavity is 30 to 60°C higher than that in the right split cavity. And / or, the preheating temperature of the left copper rod is 30 to 60°C higher than that of the right copper rod.

2. The continuous extrusion control method for asymmetric copper microchannel profiles as described in claim 1, characterized in that: In the master equation for uniform equilibrium flow, R is 8.314 J / (mol·K).

3. The continuous extrusion control method for asymmetric copper microchannel profiles as described in claim 1, characterized in that: The welding length L of the welding chamber 焊合 The value is 4 to 6 mm, and it is consistent in the left and right directions.

4. The continuous extrusion control method for asymmetric copper microchannel profiles as described in claim 1, characterized in that: The width W of the welding chamber 焊合 It is 1-2 mm wider than the total width W of the pre-prepared profile.

5. A die for continuous extrusion production of asymmetric copper microchannel profiles, characterized in that, include: The upper and lower molds are coaxially assembled; The upper mold is provided with completely independent left and right flow-dividing cavities, which correspond to the feed ports of the left and right copper rods, respectively. The outlets of the left and right branching cavities symmetrically converge into the welding chamber at the center of the mold, and the downstream of the welding chamber is connected to the vertical discharge shaping working belt; The equivalent depth H of the flow channels in the left and right flow dividers is calculated using the method described in any one of claims 1-4. 流左 With H 流右 and average depth of the welding chamber .

6. A continuous extrusion production method for asymmetric copper microchannel profiles, characterized in that, Includes the following steps: Pre-treatment of billet: Peel off the surface of the left and right copper rods to remove oxide scale and oil stains, and preheat to 150-300℃ to ensure stable friction coefficient; Parameter control: Preheat the mold to 500-650℃, calculate and control the mold parameters according to the method described in any one of claims 1-4, and then perform welding and traction to produce profiles; Shaping and control: After the profile is vertically demolded, the temperature of the profile is rapidly reduced to below 100℃ by annular air cooling and water mist cooling, and vertical correction and torsion correction are performed to obtain an asymmetric copper microchannel profile.

7. The continuous extrusion production method of the asymmetric copper microchannel profile as described in claim 6, characterized in that, The outlet temperature of the welding chamber is 550–650°C.

8. The continuous extrusion production method of the asymmetric copper microchannel profile as described in claim 6, characterized in that, The rotational speed fluctuation of the left and right extrusion rollers shall not exceed ±0.5 rpm, and the start and stop of the left and right extrusion rollers shall adopt a ramp-type acceleration and deceleration, with acceleration and deceleration not exceeding 1 rpm / s.

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