Aluminum alloy casting liquid cooling heat dissipation circulating system capable of monitoring temperature
By adopting Al-Ce-La series aluminum alloys and ultra-high vacuum casting technology, combined with a four-level sealing and temperature monitoring module, the problems of overheating, blistering and insufficient density of traditional aluminum alloys in high-temperature brazing process have been solved, achieving stable high-temperature operation and full-process temperature monitoring, thus improving the safety and reliability of the equipment.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- DONGGUAN ZHONGDIAN AIHUA ELECTRONICS
- Filing Date
- 2026-06-26
- Publication Date
- 2026-07-28
AI Technical Summary
Traditional aluminum alloy materials cannot withstand high-temperature brazing of 605℃, are prone to overheating and blistering, have insufficient density leading to leakage, and lack full-process multi-node temperature monitoring, which cannot meet the high-temperature working environment requirements of high-power equipment.
The heat dissipation substrate module is made of Al-Ce-La series high temperature resistant cast aluminum alloy. It combines ultra-high vacuum casting process and four-level sealing structure with three-dimensional hollow fin flow channel and temperature monitoring module to achieve stable operation at 605℃ and real-time temperature monitoring throughout the process.
It solves the problem of overheating and blistering during high-temperature brazing, improves the density of castings, extends service life, and enhances the safety and reliability of the equipment through multi-node temperature monitoring, adapting to the compact installation requirements of high-power equipment.
Smart Images
Figure CN122476590A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of non-ferrous metal material preparation and precision forming technology, specifically to a liquid cooling heat dissipation circulation system for aluminum alloy casting that can monitor temperature. Background Technology
[0002] With the rapid development of high-power chips and energy storage devices, liquid cooling heat dissipation structural components are required to withstand high temperatures, be highly dense, be highly sealed, and have a long lifespan. Traditional cast aluminum alloy solidus is only 500-580℃, and it is prone to overheating, blistering, cracking, and leakage when brazing at temperatures above 600℃. At the same time, the castings have low density and many internal pores, making them prone to bulging and failure at high temperatures.
[0003] In the prior art, Chinese Patent No. CN224153434U discloses an aluminum alloy heat dissipation structure for a liquid cooling heat dissipation device in an energy storage system. The structure includes an aluminum alloy heat dissipation body with a rectangular cross-section. Multiple heat dissipation through-holes are provided on the body. The upper and lower inner walls of the heat dissipation through-holes are corrugated heat-conducting surfaces with multiple heat-conducting teeth. Two heat dissipation ribs are fixedly connected to the left and right sides of the upper surface of the body. The heat-conducting teeth are arc-shaped. Multiple heat-conducting teeth are evenly distributed along the upper and lower inner walls of the heat dissipation through-holes. The heat dissipation ribs are perpendicular to the body and flush with the sides of the body. The width of the heat dissipation ribs is less than the width of the first connecting rib. An extension block is located below the upper surface of the heat dissipation ribs and forms a protrusion. Multiple connecting ribs are formed between the heat dissipation through-holes. This design not only reduces the overall weight but also maintains the structural strength of the aluminum alloy heat dissipation body, making it less prone to deformation under pressure. Simultaneously, the corrugated heat-conducting surface increases the contact area between the coolant after heat absorption and the aluminum alloy heat dissipation body, improving the heat dissipation effect of the aluminum alloy heat dissipation structure.
[0004] Furthermore, Chinese patent CN117564617A discloses a manufacturing method for a microchannel aluminum alloy liquid-cooled large panel with status monitoring. This method includes processing a finned cover plate, with the cover plate and base plate made of 5-series aluminum alloy. The finned cover plate and base plate are welded together using a low-temperature, low-deformation friction stir welding process. A narrow-shoulder stirring head is used, and water or coolant is filled into the microchannel during welding, circulating to keep the fin temperature below 100°C. Post-weld heat treatment and machining are then performed to form the microchannel aluminum alloy liquid-cooled large panel. Finally, it is welded to an aluminum-based packaged fiber optic sensor using a low-temperature spot welding process to form a microchannel aluminum alloy liquid-cooled large panel with status monitoring. This method enables low-deformation welding of high-density fins, avoiding damage to high-density, high aspect ratio fins that could lead to blockage and reduced heat dissipation capacity, increasing the heat exchange area of the flow channel, and simultaneously achieving status monitoring of the large panel.
[0005] The aforementioned device, using conventional aluminum alloy materials, still cannot meet the requirements of the 605℃ high-temperature brazing process, nor can it match the vacuum casting process of Al-Ce-La series high-temperature resistant cast aluminum alloys. It still suffers from problems such as high-temperature overheating and blistering, and insufficient casting density leading to high-temperature bulging and leakage. Furthermore, it cannot simultaneously achieve real-time temperature monitoring of multiple nodes throughout the entire heat dissipation process, making it difficult to adapt to the heat dissipation reliability requirements of high-power equipment operating in high-temperature environments. Summary of the Invention
[0006] The purpose of this invention is to provide a liquid cooling heat dissipation circulation system for aluminum alloy casting that can monitor temperature, so as to solve the problems mentioned in the background art that traditional aluminum alloys cannot withstand high-temperature brazing, are prone to overheating and blistering, have insufficient density leading to leakage, and lack full-process multi-node temperature monitoring.
[0007] To achieve the above objectives, the present invention provides the following technical solution: a liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability, comprising a cast aluminum alloy heat dissipation substrate module, a heat exchange module for a heat spreader plate, a refrigerant circulation channel module, a refrigerant charging and condensation module, a temperature monitoring module, and a vacuum casting and brazing integrated structure module. The cast aluminum alloy heat dissipation substrate module is made of Al-Ce-La series high-temperature resistant cast aluminum alloy. The cast aluminum alloy heat dissipation substrate module is cast at 730±10℃ and can withstand a high temperature of 605℃ without bubbling or burning. The refrigerant circulation channel module has built-in refrigerant, which achieves self-circulating heat dissipation through evaporation and condensation, and the temperature monitoring module collects the temperature of the heat source and the heat dissipation fins in real time.
[0008] Furthermore, the cast aluminum alloy heat dissipation substrate module is formed using an ultra-high vacuum casting process. The casting equipment is a 4500T cold chamber die casting machine. The mold adopts a four-level sealing structure, the cavity vacuum degree is <25mbar, and the casting density reaches 2.8g / cm³.
[0009] Furthermore, the four-level sealing structure includes: a trapezoidal seal between the mold frame A plate and the front mold core, a U-shaped seal at the bottom of the front and rear mold cores, a trapezoidal seal between the rear mold core slider seat and the vent block, a seal between the sprue and the feed cylinder, and a trapezoidal seal on the square iron contact surface.
[0010] Furthermore, it also includes a bottom-outlet water supply structure, which, together with a large mold drain and a wave pressure valve, allows for rapid air extraction, achieving high vacuum and high sealing performance in the mold cavity, thus solving the problems of high-temperature bulging and sealing failure in castings.
[0011] Furthermore, the cast aluminum alloy heat dissipation substrate module and the heat exchange module of the heat spreader are connected by high-temperature brazing of dissimilar aluminum alloys at a brazing temperature of 605°C.
[0012] Furthermore, the refrigerant charging and condensation module adopts a dual-chamber independent quantitative charging process, with the chamber vacuum degree ≤ before charging. .
[0013] Furthermore, the heat exchange module of the heat spreader is made of 3-series or 4-series wrought aluminum alloy, with a brazed joint burst pressure ≥7MPa and a helium leak detection rate of ≤2.5MPa. .
[0014] Furthermore, the temperature monitoring module monitors the heat source temperature, heat dissipation substrate temperature, refrigerant evaporation temperature, and condensation temperature in real time, and supports data acquisition and over-temperature alarm.
[0015] Furthermore, the refrigerant circulation channel module is a three-dimensional hollow finned channel with a turbulence enhancement structure on the inner wall of the channel to improve the refrigerant evaporation heat exchange efficiency.
[0016] Furthermore, the corners of the cast aluminum alloy heat dissipation substrate module are provided with assembly stops for quick coaxial positioning with the heat exchange module of the heat spreader, ensuring the brazing assembly accuracy and the coaxiality of the flow channel.
[0017] Compared with the prior art, the beneficial effects of the present invention are:
[0018] (1) By adopting Al-Ce-La rare earth aluminum alloy, stable operation at 605℃ is achieved, breaking through the high temperature bottleneck of traditional cast aluminum, solving the problem of easy overheating and blistering of traditional cast aluminum alloy during high temperature brazing, and ensuring the structural stability of the heat dissipation structure under high temperature process and working environment.
[0019] (2) The ultra-high vacuum die casting process with four-level sealing and multi-level air extraction can effectively reduce the internal porosity defects of the casting, greatly improve the density of the casting, avoid the problem of casting bulging failure caused by gas expansion in the pores during high-temperature use, extend the service life of the heat dissipation circulation system, and has high density, no pores, and no bulging at high temperatures.
[0020] (3) The integrated temperature monitoring module can collect temperature data from multiple nodes in real time, and can keep track of the working status of the heat dissipation system in a timely manner. The over-temperature alarm function can provide early warning of heat dissipation failure, which improves the safety and reliability of equipment operation and enhances the safety and intelligence level of the system.
[0021] (4) The three-dimensional hollow finned flow channel combined with the inner wall turbulence enhancement structure effectively improves the heat exchange efficiency of the refrigerant. With the self-circulating refrigerant heat dissipation design, no additional power components are required, the structure is more compact, the heat dissipation performance is more stable, and it is suitable for the compact installation requirements of high power density equipment. At the same time, the positioning design of the assembly stop ensures the assembly accuracy of dissimilar aluminum alloy brazing, which can effectively avoid the decrease in heat dissipation efficiency caused by flow channel misalignment, and improve the qualification rate and heat dissipation stability of the finished product. Attached Figure Description
[0022] Figure 1This is a schematic diagram of the overall structure of the present invention;
[0023] Figure 2 This is a schematic diagram of the working steps of the present invention;
[0024] Figure 3 This is a schematic diagram of the temperature judgment structure of the present invention;
[0025] Figure 4 This is a schematic diagram of the temperature control logic structure of the present invention;
[0026] Figure 5 This is a schematic diagram of the four-level sealing structure steps of the present invention.
[0027] In the diagram: 1. Cast aluminum alloy heat dissipation substrate module; 2. Heat exchanger module; 3. Refrigerant circulation channel module; 4. Refrigerant charging and condensation module; 5. Temperature monitoring module; 6. Four-stage sealing structure; 7. Vacuum casting and brazing integrated structure module. Detailed Implementation
[0028] The technical solutions of the embodiments 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, and 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.
[0029] Example 1: Please refer to Figure 1 - Figure 2 The present invention provides the following technical solution: a liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability, comprising a cast aluminum alloy heat dissipation substrate module 1, a heat exchange module 2, a refrigerant circulation channel module 3, a refrigerant charging and condensation module 4, a temperature monitoring module 5, and a vacuum casting and brazing integrated structure module. The cast aluminum alloy heat dissipation substrate module 1 is made of Al-Ce-La series high temperature resistant cast aluminum alloy. The cast aluminum alloy heat dissipation substrate module 1 is cast at 730±10℃ and can withstand a high temperature of 605℃ without bubbling or burning. The refrigerant circulation channel module 3 has built-in refrigerant and achieves self-circulating heat dissipation through evaporation and condensation. The temperature monitoring module 5 collects the temperature of the heat source and the heat dissipation fins in real time.
[0030] The heat dissipation substrate is formed using an ultra-high vacuum casting process, and a high-density casting is obtained by combining it with a four-level sealed mold structure. This meets the requirements of subsequent high-temperature brazing, avoiding the problem of insufficient density in traditional low-pressure castings, which leads to bulging failure during high-temperature brazing. This improves the product yield and structural reliability. The heat dissipation substrate, made of Al-Ce-La series high-temperature resistant cast aluminum alloy, can withstand a brazing temperature of 605℃ without overheating or blistering. This solves the problem that traditional aluminum alloy materials cannot be matched with this high-temperature brazing process, and achieves a reliable connection between the cast aluminum alloy heat dissipation substrate and the deformed aluminum alloy heat spreader. The resulting brazed joint has high strength and good sealing performance, and can withstand the refrigerant working pressure for a long time without leakage. At the same time, the system can simultaneously collect temperature data from multiple nodes, including the heat source, heat dissipation substrate, refrigerant evaporation side, and condensation side, through temperature monitoring module 5. The staff can monitor the working status of the heat dissipation system in real time. When the monitored temperature exceeds the safety threshold, an over-temperature alarm is automatically triggered, which can promptly prompt maintenance personnel to troubleshoot the fault and prevent high-power heat sources from overheating and being damaged due to insufficient heat dissipation, thus greatly improving the safety of the entire equipment operation.
[0031] Example 2: Based on Example 1, this example solves the problem of poor sealing performance in existing aluminum alloy castings. Please refer to [link / reference]. Figure 2 - Figure 3 The four-level sealing structure 6 was also disclosed, and its specific structure is as follows: The cast aluminum alloy heat dissipation base module 1 is formed by ultra-high vacuum casting process, and the casting equipment is a 4500T cold chamber die casting machine. The mold adopts the four-level sealing structure 6, the cavity vacuum degree is <25mbar, and the casting density reaches 2.8g / cm³. The four-level sealing structure 6 includes: trapezoidal seal between mold frame A plate and front mold core, U-shaped seal at the bottom of front and rear mold cores, trapezoidal seal between rear mold core slider seat and vent block, seal between sprue and feed cylinder, and trapezoidal seal on square iron contact surface. It also includes a bottom direct water outlet structure, and works with mold large vent and wave pressure valve for rapid air extraction to achieve high vacuum degree and high sealing performance of the cavity, solving the problems of high temperature bulging and sealing failure of casting. The cast aluminum alloy heat dissipation base module 1 and the heat exchange module 2 of the heat exchange plate are connected by high temperature brazing of dissimilar aluminum alloys, and the brazing temperature is 605℃.
[0032] When the aluminum alloy casting liquid cooling heat dissipation circulation system is working, the heat generated by battery charging and discharging is first transferred to the cast aluminum alloy heat dissipation substrate module 1. After rapid temperature homogenization by the high-density substrate, the heat is introduced into the connected heat exchange module 2, and then transferred to the refrigerant circulation channel module 3. The built-in refrigerant absorbs the heat and evaporates, flowing upward to the refrigerant charging and condensation module. After releasing heat in the condensation chamber, it re-condenses into a liquid state and flows back to the heat absorption area of the channel by gravity, completing the automatic circulation heat dissipation. During this process, the temperature monitoring module 5 continuously collects real-time temperature data of the heat source, heat dissipation substrate, refrigerant evaporation side and condensation side. When the temperature exceeds the preset safety threshold, an over-temperature alarm is automatically triggered. The system reminds operators to adjust operating conditions promptly to ensure the safe operation of the entire energy storage system. The four-stage sealed vacuum casting structure, combined with a rapid evacuation scheme, continuously maintains a low vacuum environment in the mold cavity, preventing gas entrapment during the casting process. This eliminates the problem of casting bulging and seal failure caused by internal gas expansion during subsequent high-temperature brazing, ensuring the structural stability of the entire liquid cooling system. Furthermore, the four-stage sealed structure uses different sealing forms such as trapezoidal and U-shaped shapes to match the structural characteristics of different mold parts, resulting in higher sealing reliability. Compared with the integrated sealing structure, it is easier to process and has a more stable sealing effect. It can be adapted to the modification of existing large-scale cold chamber die-casting equipment without the need for customized special sealing mold frames, resulting in low modification costs and strong practicality.
[0033] Example 3: Based on Example 1, this example solves the problem of inaccurate temperature detection in existing aluminum alloy casting methods. Please refer to [link / reference]. Figure 3 - Figure 5 The temperature monitoring module 5 was also disclosed, and its specific structure is as follows: The refrigerant charging and condensation module 4 adopts a dual-chamber independent quantitative charging process, and the vacuum degree of the chamber before charging is ≤ The heat exchange module 2 of the heat spreader is made of 3-series or 4-series wrought aluminum alloy, with a burst pressure of ≥7MPa for the brazed joint and a helium leak detection rate of ≤2.5MPa. The temperature monitoring module 5 monitors the heat source temperature, heat dissipation substrate temperature, refrigerant evaporation temperature and condensation temperature in real time, and supports data acquisition and over-temperature alarm. The refrigerant circulation channel module 3 is a three-dimensional hollow fin channel with a turbulence enhancement structure on the inner wall of the channel to improve the refrigerant evaporation heat exchange efficiency. The corners of the cast aluminum alloy heat dissipation substrate module 1 are provided with assembly stops for quick coaxial positioning with the heat exchange module 2 of the heat spreader, ensuring the brazing assembly accuracy and the coaxiality of the channel.
[0034] After positioning is achieved through assembly stops, misalignment between the heat spreader and the heat sink substrate during brazing can be effectively prevented, ensuring that the coaxiality of the refrigerant flow channel meets design requirements and preventing flow channel misalignment from affecting refrigerant circulation efficiency. The three-dimensional hollow finned flow channel, combined with the inner wall turbulence enhancement structure, can break the boundary layer during refrigerant flow, improve the heat exchange efficiency between the refrigerant and the inner wall of the flow channel, and thus improve the heat dissipation capacity of the entire system. The independent quantitative vacuum charging process can precisely control the refrigerant charging amount in each chamber, avoiding the impact of charging amount deviation on the circulation heat dissipation effect. At the same time, the high vacuum charging environment avoids the presence of non-condensable residues in the chamber. The gas influences the refrigerant evaporation and condensation cycle, ensuring stable heat dissipation efficiency. The brazed joints meet the requirements of high burst pressure and low leakage rate, and can withstand the internal pressure of the refrigerant cycle for a long time without leakage or cracking, thus improving the long-term service life and operational safety of the system. At the same time, real-time multi-node temperature monitoring can provide a more comprehensive understanding of the working status of each part of the heat dissipation system, avoiding misjudgment by single-point monitoring or failure to detect local overheating problems in time. Combined with the over-temperature alarm function, it can quickly warn of fault risks, facilitate timely operation and maintenance adjustments, and ensure that high-power equipment can still operate stably and reliably in high-temperature environments.
[0035] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; 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. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.
[0036] Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.
Claims
1. A liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability, comprising a cast aluminum alloy heat dissipation substrate module (1), a heat exchange module (2), a refrigerant circulation channel module (3), a refrigerant charging and condensation module (4), a temperature monitoring module (5), and a vacuum casting and brazing integrated structure module (7), characterized in that: The cast aluminum alloy heat dissipation substrate module (1) is made of Al-Ce-La series high temperature resistant cast aluminum alloy. The cast aluminum alloy heat dissipation substrate module (1) is cast at 730±10℃ and can withstand 605℃ high temperature without bubbling or burning. The refrigerant circulation channel module (3) has built-in refrigerant and achieves self-circulation heat dissipation through evaporation and condensation. The temperature monitoring module (5) collects the temperature of the heat source and heat dissipation fins in real time.
2. The liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 1, characterized in that: The cast aluminum alloy heat dissipation substrate module (1) is formed by ultra-high vacuum casting process. The casting equipment is a 4500T cold chamber die casting machine. The mold adopts a four-level sealing structure (6). The cavity vacuum degree is <25mbar and the density of the casting reaches 2.8g / cm³.
3. The liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 2, characterized in that: The four-level sealing structure (6) includes: trapezoidal seal between mold frame A plate and front mold core, U-shaped seal at the bottom of front and rear mold cores, trapezoidal seal between rear mold core slider seat and vent block, seal between sprue and feed cylinder, and trapezoidal seal on the contact surface of square iron.
4. The liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 1, characterized in that: It also includes a bottom-outlet water supply structure, which, together with the mold exhaust valve and wave pressure valve, allows for rapid air extraction, achieving high vacuum and high sealing performance in the mold cavity, thus solving the problems of high-temperature bulging and sealing failure in castings.
5. A liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 1, characterized in that: The cast aluminum alloy heat dissipation substrate module (1) and the heat exchange module (2) are connected by high-temperature brazing of dissimilar aluminum alloys, with a brazing temperature of 605℃.
6. A liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 1, characterized in that: The refrigerant charging and condensation module (4) adopts a dual-chamber independent quantitative charging process, and the vacuum degree of the chamber before charging is ≤ .
7. A liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 1, characterized in that: The heat exchange module (2) of the heat spreader plate is made of 3-series or 4-series wrought aluminum alloy, with a brazed joint burst pressure ≥7MPa and a helium leak detection rate of ≤2.5MPa. .
8. A liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 1, characterized in that: The temperature monitoring module (5) monitors the heat source temperature, heat dissipation substrate temperature, refrigerant evaporation temperature and condensation temperature in real time, and supports data acquisition and over-temperature alarm.
9. A liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 1, characterized in that: The refrigerant circulation channel module (3) is a three-dimensional hollow fin channel with a turbulence enhancement structure on the inner wall of the channel to improve the refrigerant evaporation heat exchange efficiency.
10. A liquid cooling heat dissipation circulation system for aluminum alloy casting with temperature monitoring capability according to claim 1, characterized in that: The cast aluminum alloy heat dissipation substrate module (1) is provided with assembly stops at the corners for quick coaxial positioning with the heat exchange module (2) of the heat exchange plate, so as to ensure the brazing assembly accuracy and the coaxiality of the flow channel.