Processing technology of integrated heat sink case

Abstract

The application belongs to the technical field of radiator case production, and particularly relates to a processing technology of an integrated radiator case, and the specific steps of the processing technology are as follows: high-thermal-conductivity alloy material pretreatment, extrusion forming, CNC fine finishing and fin height expansion, integrated processing of heat pipe installation groove, modular expansion fin assembly, composite welding, surface anti-corrosion treatment, precision detection and correction, general assembly and air duct integration; the application adopts the combined technology of optimized material pretreatment, extrusion pre-forming, CNC fine finishing composite forming and modular fin expansion, and through the synergistic logic of extrusion for rough blank, CNC for fine finishing and modular reinforcement, the fin structure limitation is broken through without sacrificing the processing efficiency and material utilization rate, and the high-end equipment heat dissipation demand is adapted.

Description

Technical Field

[0001] This invention relates to the field of radiator chassis manufacturing technology, specifically to a processing technology for an integrated radiator chassis. Background Technology

[0002] A heatsink chassis is a computer hardware device that deeply integrates the chassis structure and heat dissipation system. Its core is to break the traditional model of separating the chassis body and the heatsink, and integrate the heat dissipation modules (such as fins, heat pipes, and heat spreaders) with the chassis shell and airflow layout. It is specifically designed for high-power and high-heat scenarios such as high-performance computers, servers, and industrial control equipment, and achieves synergistic optimization of heat dissipation efficiency, space utilization and structural stability.

[0003] The existing integrated radiator enclosure manufacturing process still presents the following technical challenges in radiator enclosure production:

[0004] The current integrated molding process has significant limitations. If extrusion molding is used to process the side panels and integrated fins of the chassis, the upper limit of fin density is limited by the strength of the extrusion die and the fluidity of the metal. Furthermore, the fin height is difficult to exceed 30mm, as excessive height can easily lead to deformation and breakage during extrusion, failing to meet the high heat dissipation requirements of high-end equipment. If CNC milling is used to process integrated fins, although it can increase fin density, the processing efficiency is extremely low. Milling the fins of a single side panel requires 2-4 hours, and the metal scrap rate is high, resulting in low material utilization.

[0005] Therefore, a processing technology for an integrated radiator chassis is proposed to solve the problems mentioned above. Summary of the Invention

[0006] The purpose of this invention is to provide a manufacturing process for an integrated heat sink chassis to solve the problems mentioned in the background art.

[0007] To achieve the above objectives, the present invention provides the following technical solution: a processing technology for an integrated radiator chassis, the specific steps of which are as follows:

[0008] Step 1: Pretreatment of high thermal conductivity alloy material: Select thermal conductivity alloy material and pretreat it.

[0009] Step 2, Extrusion Molding: The high thermal conductivity alloy material is extruded to achieve initial shaping;

[0010] Step 3, CNC finishing and fin height extension: Based on the extruded blank, CNC finishing is used to increase fin density and extend fin height.

[0011] Step 4: Integrated machining of heat pipe mounting slots: The machining of heat pipe mounting slots is completed simultaneously during the CNC finishing stage;

[0012] Step 5: Modular expansion fin assembly: To meet the high heat dissipation requirements of ultra-high-end equipment, modular expansion fins are added;

[0013] Step 6, Composite Welding: A composite process of brazing and laser welding is used to ensure the connection quality between the heat pipe and the chassis wall and heat spreader.

[0014] Step 7, Surface anti-corrosion treatment: Micro-arc oxidation and sealing treatment processes are used to solve the problem of easy oxidation of fins and extend service life;

[0015] Step 8, Accuracy Inspection and Calibration: Inspect the dimensions and thermal resistance of the chassis and make corresponding corrections;

[0016] Step 9, Assembly and Airflow Integration: Fix the partitioned airflow guide plate to the preset position inside the chassis with bolts, install the fan assembly, assemble the heat spreader, and connect the heat spreader and heat pipes by brazing to form a complete heat dissipation circuit.

[0017] Preferably, the specific steps of step one are as follows: using 6063-T6 optimized aluminum alloy, heating the aluminum alloy ingot to 500-520℃ and holding it for 6 hours, using alkaline washing and acid washing to remove the oxide scale on the surface of the ingot, so as to avoid the oxide scale embedding into the fins during extrusion and causing cracking, and spraying a graphite-based lubricating film on the surface of the ingot to reduce the friction between the ingot and the mold during extrusion and improve the integrity of the fin forming.

[0018] Preferably, the specific steps of step two are as follows: a split-type combined mold is adopted, and the fin groove of the mold core adopts a gradient flow channel to adapt to the metal flow characteristics and avoid stress concentration at the root of the fin. At the same time, the mold core is made of H13 hot work die steel and nitrided to improve the mold strength and support higher density fin extrusion; the extrusion temperature is set to 520-540℃, the extrusion speed is set to 3-5mm / s, and the extrusion ratio is 15:1. Low speed and high pressure ensure that the metal fully fills the fin groove; the chassis side plate and basic fin are extruded and formed in one step. At this time, the fin is a rough blank structure, which does not require a lot of subsequent milling and only fine finishing is needed.

[0019] Preferably, the specific steps of step three are as follows: Based on the extruded 50 fins / inch, some redundant fin material is removed by milling to increase the density to 80-100 fins / inch. Based on the extruded 25mm fins, the fin height is extended to 40-50mm by layer milling. After each layer of milling, air cooling is used to reduce the temperature. After milling, the parallelism error of the fins is ≤0.05mm. The surface of the fins is lightly ground with a CNC grinding head to reduce the roughness to Ra0.4-0.6μm and reduce wind resistance.

[0020] Preferably, the specific steps of step four are as follows: an arc-shaped groove is milled on the inner side of the chassis side panel, the groove length is consistent with the heat pipe length, and a combination of milling and grinding is used. After milling, the groove wall is ground with a diamond grinding wheel to achieve a surface roughness of Ra0.2μm, ensuring that the heat pipe fits tightly with the groove wall and reducing thermal resistance. Taking the fin root as a reference, the parallelism error between the heat pipe groove and the fin is ensured to be ≤0.03mm to avoid interference between the heat pipe and the fin after installation.

[0021] Preferably, the specific steps of step five are as follows: high-density fin groups are processed separately using stamping and brazing processes. The extended fin groups are spliced ​​with the integrated fins by bolt fixing and thermal grease filling at the mounting holes reserved on the side panel of the chassis. The gap at the splice is ≤0.1mm, and the thermal conductivity of the thermal grease is ≥4.0W / (m・K).

[0022] Preferably, the specific steps of step six are as follows: apply brazing paste into the heat pipe mounting groove, embed the heat pipe into the groove, place the whole thing into the brazing furnace, heat to 600℃, keep warm for 15 minutes to achieve large-area bonding welding between the heat pipe and the groove wall, use a fiber laser welding machine to repair the gap after brazing, the repair welding speed is 5mm / s to avoid false welding, and use a thermal imager to detect the temperature distribution at the welding point to ensure that there are no local hot spots.

[0023] Preferably, the specific steps of step seven are as follows: In the electrolyte, a ceramic layer with a thickness of 10-15μm and a hardness of HV500-600 is formed on the surface of the chassis by high-voltage discharge of 1000V. The micropores of the micro-arc oxidation layer are filled by soaking in an organosilicon sealant.

[0024] Preferably, the specific steps of step eight are as follows: use a coordinate measuring machine to detect key dimensions, conduct thermal simulation tests to detect the thermal resistance of the integrated heat dissipation module, and perform CNC micro-correction on products with out-of-tolerance dimensions to ensure the compatibility of the hardware mounting position with the heat spreader and fins.

[0025] Compared with the prior art, the beneficial effects of the present invention are:

[0026] This application adopts a combination of optimized material pretreatment, extrusion preforming, CNC precision repair and molding, and modular fin expansion. Through the collaborative logic of extrusion for rough blanking, CNC for fine repair, and modular reinforcement, it breaks through the limitations of fin structure without sacrificing processing efficiency and material utilization, and adapts to the heat dissipation needs of high-end equipment. Attached Figure Description

[0027] Figure 1 This is a flowchart of the processing steps in this invention. 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:

[0030] Please see Figure 1 The present invention provides a technical solution:

[0031] A manufacturing process for an integrated heatsink chassis, the specific steps of which are as follows:

[0032] Step 1: Pretreatment of high thermal conductivity alloy material: Select thermal conductivity alloy material and pretreat it.

[0033] Step 2, Extrusion Molding: The high thermal conductivity alloy material is extruded to achieve initial shaping;

[0034] Step 3, CNC finishing and fin height extension: Based on the extruded blank, CNC finishing is used to increase fin density and extend fin height.

[0035] Step 4: Integrated machining of heat pipe mounting slots: The machining of heat pipe mounting slots is completed simultaneously during the CNC finishing stage;

[0036] Step 5: Modular expansion fin assembly: To meet the high heat dissipation requirements of ultra-high-end equipment, modular expansion fins are added;

[0037] Step 6, Composite Welding: A composite process of brazing and laser welding is used to ensure the connection quality between the heat pipe and the chassis wall and heat spreader.

[0038] Step 7, Surface anti-corrosion treatment: Micro-arc oxidation and sealing treatment processes are used to solve the problem of easy oxidation of fins and extend service life;

[0039] Step 8, Accuracy Inspection and Calibration: Inspect the dimensions and thermal resistance of the chassis and make corresponding corrections;

[0040] Step 9, Assembly and Airflow Integration: Fix the partitioned airflow guide plate to the preset position inside the chassis with bolts. The distance between the guide plate and the fins should be ≥10mm to ensure smooth airflow. Install the fan assembly, with a front intake fan, a rear exhaust fan, and a side auxiliary fan. The parallelism error between the fan and the fins should be ≤0.5mm. Assemble the heat spreader, fitting it to the CPU / graphics card mounting position. The heat spreader and heat pipes are connected by brazing to form a complete heat dissipation circuit.

[0041] The specific steps of step one are as follows: Using 6063-T6 optimized aluminum alloy, the aluminum alloy ingot is heated to 500-520℃ and held for 6 hours to eliminate internal component segregation and stress, ensuring uniform metal flow during extrusion; alkaline washing (5% NaOH solution, 50℃, 5 minutes) and acid washing (10%) are then performed. The solution (at room temperature, for 3 minutes) removes the oxide scale from the surface of the ingot, preventing the oxide scale from embedding into the fins during extrusion and causing cracking. A graphite-based lubricating film with a thickness of 0.05 mm is sprayed onto the surface of the ingot to reduce the friction between the ingot and the mold during extrusion and improve the integrity of the fin forming.

[0042] The use of 6063-T6 optimized aluminum alloy improves both metal fluidity and tensile strength, solving the problems of fin breakage and incomplete forming during traditional aluminum alloy extrusion. Homogenization annealing eliminates internal stress and compositional segregation in the ingot, ensuring uniform metal flow during extrusion and avoiding inconsistent fin density. The combination of alkaline washing and acid washing thoroughly removes oxide scale from the ingot surface, preventing oxide scale embedding in the fins and causing extrusion cracking, thus improving the yield rate. The graphite-based lubricating film reduces friction between the ingot and the die, allowing the metal to fully fill the fin slots, making it particularly suitable for the extrusion forming of high-density fins and laying the foundation for subsequent fin density increases to 80-100 fins / inch.

[0043] The specific steps of step two are as follows: A split-type combined mold is adopted, consisting of a mold core, a mold sleeve, and a flow divider cone. The fin groove of the mold core adopts a gradient flow channel, with an inlet width of 0.8mm to an outlet width of 0.5mm, which is adapted to the metal flow characteristics and avoids stress concentration at the root of the fin. At the same time, the mold core is made of H13 hot work die steel and nitrided, with a surface hardness of HV1000, which improves the mold strength and supports higher density fin extrusion. The extrusion temperature is set to 520-540℃, the extrusion speed is set to 3-5mm / s, and the extrusion ratio is 15:1. Low speed and high pressure ensure that the metal fully fills the fin groove. The machine side plate (thickness 2mm) and the basic fin (density 50 pieces / inch, height 25mm) are extruded in one step. At this time, the fin is a rough blank structure with a surface roughness Ra1.2-1.6μm, which does not require a lot of subsequent milling and only fine finishing.

[0044] The gradient flow channel adapts to the metal flow characteristics, avoiding stress concentration at the root of the fins. H13 hot work die steel and nitriding treatment improve the strength of the die, breaking through the limitations of traditional dies on fin density and extending the die life. The extruded fins are rough blanks, requiring only fine finishing without extensive milling, which greatly shortens the processing cycle and paves the way for improved efficiency in subsequent CNC fine finishing.

[0045] The specific steps of step three are as follows: Based on the extruded 50 fins / inch, milling is used to remove some redundant fin material, increasing the density to 80-100 fins / inch. Based on the extruded 25mm fins, the fin height is extended to 40-50mm through layer milling, with each layer milling height being 5mm, for a total of 3 layers. After each layer is milled, air cooling is used to prevent fin deformation caused by high temperature. After milling, the parallelism error of the fins is ≤0.05mm. The surface of the fins is lightly ground using a CNC grinding head (800# grit) to reduce the roughness to Ra0.4-0.6μm, thereby reducing wind resistance.

[0046] Based on the extrusion of 50 fins / inch, milling is used to refine the fin density to 80-100 fins / inch, solving the problems of low density and insufficient heat dissipation area of ​​traditional extruded fins. This meets the high heat dissipation requirements of high-end equipment. Layered milling extends the fin height from 25mm in extrusion to 40-50mm, breaking through the limitation of ≤30mm fin height in traditional extrusion, further improving heat dissipation efficiency. Air cooling avoids fin deformation caused by high temperature during milling, ensuring fin parallelism error. Light grinding with a CNC grinding head reduces the fin roughness to Ra0.4-0.6μm, reducing airflow resistance and preventing hot air retention caused by rough fin surface, thus improving the overall heat dissipation effect.

[0047] The specific steps of step four are as follows: Mill an arc-shaped groove on the inner side of the chassis side panel (at the root of the fins). The radius matches the diameter of the heat pipe, the gap is ≤0.05mm, and the length of the groove is consistent with the length of the heat pipe. A combination of milling and grinding is used. After milling, the groove wall is ground with a diamond grinding wheel to achieve a surface roughness of Ra0.2μm. This ensures that the heat pipe fits tightly with the groove wall and reduces thermal resistance. Using the root of the fins as a reference, ensure that the parallelism error between the heat pipe groove and the fins is ≤0.03mm to avoid interference between the heat pipe and the fins after installation.

[0048] The arc-shaped groove is precisely matched with the diameter of the heat pipe, and the roughness of the groove wall Ra is Ra0.2μm by diamond grinding wheel grinding, which ensures that the heat pipe and the groove wall fit tightly, reducing the thermal resistance caused by air gaps. This solves the problems of rough processing and low thermal conductivity of traditional mounting grooves. With the root of the fin as the reference, the parallelism error between the heat pipe groove and the fin is guaranteed to be ≤0.03mm, avoiding interference between the heat pipe and the fin after installation, ensuring the integrity of the heat dissipation circuit, and simplifying the subsequent assembly process.

[0049] The specific steps of step five are as follows: High-density fin assemblies are processed separately using stamping and brazing processes, with a density of 100 fins / inch and a height of 30mm. The mounting holes are pre-drilled on the side panel of the chassis. The fin assemblies are processed simultaneously during CNC precision finishing. The extended fin assemblies are spliced ​​with the integrated fins by bolt fixing and thermal grease filling. The gap at the splice is ≤0.1mm, and the thermal conductivity of the thermal grease is ≥4.0W / (m・K).

[0050] Individually processed high-density fin assemblies improve material utilization and solve the problem that the single structure of traditional integrated processes cannot adapt to different heat dissipation needs. The gap at the splicing point is ≤0.1mm, and thermal grease ensures smooth heat transfer. Whether to install extended fins can be selected according to equipment needs, realizing flexible switching between basic heat dissipation and strong heat dissipation. Moreover, the extended fins can be replaced individually, reducing maintenance costs.

[0051] The specific steps of step six are as follows: Apply brazing paste (composition: Al-Si-Cu, melting point 580℃) to the heat pipe mounting groove, embed the heat pipe into the groove, place the whole thing into the brazing furnace, heat to 600℃, hold for 15 minutes to achieve large-area bonding welding between the heat pipe and the groove wall, use a fiber laser welding machine (power 500W, spot diameter 0.2mm) to repair the gap (≤0.05mm) after brazing, the repair welding speed is 5mm / s to avoid cold welding, and use a thermal imager to detect the temperature distribution at the welding point to ensure that there are no local hot spots.

[0052] The specific steps of step seven are as follows: In the electrolyte (sodium silicate and sodium hydroxide system), a ceramic layer with a thickness of 10-15μm and a hardness of HV500-600 is formed on the surface of the chassis (including fins) by 1000V high-voltage discharge. The layer is then immersed in an organosilicon sealant (at room temperature for 10 minutes) to fill the micropores of the micro-arc oxidation layer, preventing dust and moisture from entering and further improving the corrosion resistance.

[0053] A 1000V high-voltage discharge forms a 10-15μm ceramic layer, which has three times the corrosion resistance of traditional anodizing. This solves the problems of easy oxidation of fins and decreased thermal conductivity after long-term use. The micropores of the ceramic layer are filled to prevent dust and moisture from entering the root of the fins, thus preventing corrosion and reducing the increase in wind resistance caused by dust accumulation, thereby extending the service life of the chassis.

[0054] The specific steps of step eight are as follows: use a coordinate measuring machine to detect key dimensions, conduct thermal simulation tests to detect the thermal resistance of the integrated heat dissipation module, and perform CNC micro-correction on products with out-of-tolerance dimensions (≤3%) to ensure the compatibility of the hardware mounting position with the heat spreader and fins.

[0055] Key dimensional tolerances are controlled within ±0.1mm, solving the problems of large dimensional deviations and assembly interference in mass production using traditional processes. Thermal simulation testing ensures that the thermal resistance of the heat dissipation module is ≤0.15℃ / W, meeting the requirements of high-end equipment. Micro-correction is performed on products with ≤3% deviation to ensure precise fit between the hardware mounting position and the heat spreader and fins, avoiding increased thermal resistance due to fitting gaps and improving product consistency.

[0056] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects. The scope of the invention is defined by the appended claims rather than the foregoing description. Therefore, all variations falling within the meaning and scope of equivalents of the claims are intended to be included within the present invention, and no reference numerals in the claims should be construed as limiting the scope of the claims.

[0057] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for an integrated radiator chassis, characterized in that, The specific steps of this processing technique are as follows: Step 1: Pretreatment of high thermal conductivity alloy material: Select thermal conductivity alloy material and pretreat it. Step 2, Extrusion Molding: The high thermal conductivity alloy material is extruded to achieve initial shaping; Step 3, CNC finishing and fin height extension: Based on the extruded blank, CNC finishing is used to increase fin density and extend fin height. Step 4: Integrated machining of heat pipe mounting slots: The machining of heat pipe mounting slots is completed simultaneously during the CNC finishing stage; Step 5: Modular expansion fin assembly: To meet the high heat dissipation requirements of ultra-high-end equipment, modular expansion fins are added; Step 6, Composite Welding: A composite process of brazing and laser welding is used to ensure the connection quality between the heat pipe and the chassis wall and heat spreader. Step 7, Surface anti-corrosion treatment: Micro-arc oxidation and sealing treatment processes are used to solve the problem of easy oxidation of fins and extend service life; Step 8, Accuracy Inspection and Calibration: Inspect the dimensions and thermal resistance of the chassis and make corresponding corrections; Step 9, Assembly and Airflow Integration: Fix the partitioned airflow guide plate to the preset position inside the chassis with bolts, install the fan assembly, assemble the heat spreader, and connect the heat spreader and heat pipes by brazing to form a complete heat dissipation circuit.

2. The processing technology of an integrated radiator chassis according to claim 1, characterized in that: The specific steps of step one are as follows: using 6063-T6 optimized aluminum alloy, heating the aluminum alloy ingot to 500-520℃ and holding it for 6 hours, using alkaline washing and acid washing to remove the oxide scale on the surface of the ingot, so as to avoid the oxide scale embedding into the fins during extrusion and causing cracking, and spraying a graphite-based lubricating film on the surface of the ingot to reduce the friction between the ingot and the mold during extrusion and improve the integrity of the fin forming.

3. The processing technology of an integrated radiator chassis according to claim 1, characterized in that: The specific steps of step two are as follows: A split-type combined mold is adopted, and the fin groove of the mold core adopts a gradient flow channel to adapt to the metal flow characteristics and avoid stress concentration at the root of the fin. At the same time, the mold core is made of H13 hot work die steel and nitrided to improve the mold strength and support higher density fin extrusion; the extrusion temperature is set to 520-540℃, the extrusion speed is set to 3-5mm / s, and the extrusion ratio is 15:

1. Low speed and high pressure ensure that the metal fully fills the fin groove; the chassis side plate and basic fin are formed by one-time extrusion. At this time, the fin is a rough blank structure, which does not require a lot of subsequent milling and only fine finishing.

4. The processing technology of an integrated radiator chassis according to claim 1, characterized in that: The specific steps of step three are as follows: Based on the extruded 50 fins / inch, milling is used to remove some redundant fin material, increasing the density to 80-100 fins / inch. Based on the extruded 25mm fins, the fin height is extended to 40-50mm through layer milling. After each layer of milling, air cooling is used to reduce the temperature. After milling, the parallelism error of the fins is ≤0.05mm. The surface of the fins is lightly ground with a CNC grinding head to reduce the roughness to Ra0.4-0.6μm, thereby reducing wind resistance.

5. The processing technology of an integrated radiator chassis according to claim 1, characterized in that: The specific steps of step four are as follows: A curved groove is milled on the inner side of the chassis side panel. The groove length is consistent with the heat pipe length. A combination of milling and grinding process is used. After milling, the groove wall is ground with a diamond grinding wheel to achieve a surface roughness of Ra0.2μm, ensuring that the heat pipe fits tightly with the groove wall and reducing thermal resistance. Taking the fin root as a reference, ensure that the parallelism error between the heat pipe groove and the fin is ≤0.03mm to avoid interference between the heat pipe and the fin after installation.

6. The processing technology of an integrated radiator chassis according to claim 1, characterized in that: The specific steps of step five are as follows: High-density fin groups are processed separately using stamping and brazing processes. The extended fin groups are spliced ​​with the integrated fins by bolt fixing and thermal grease filling at the pre-reserved mounting holes on the side panel of the chassis. The gap at the splice is ≤0.1mm, and the thermal conductivity of the thermal grease is ≥4.0W / (m・K).

7. The processing technology of an integrated radiator chassis according to claim 1, characterized in that: The specific steps of step six are as follows: apply brazing paste into the heat pipe mounting groove, embed the heat pipe into the groove, place the whole thing into the brazing furnace, heat to 600℃, keep warm for 15 minutes to achieve large-area bonding welding between the heat pipe and the groove wall, use a fiber laser welding machine to repair the gap after brazing, the repair welding speed is 5mm / s to avoid false welding, and use a thermal imager to detect the temperature distribution at the welding point to ensure that there are no local hot spots.

8. The processing technology of an integrated radiator chassis according to claim 1, characterized in that: The specific steps of step seven are as follows: In the electrolyte, a ceramic layer with a thickness of 10-15μm and a hardness of HV500-600 is formed on the surface of the chassis by high-voltage discharge of 1000V. The micropores of the micro-arc oxidation layer are filled by soaking in an organosilicon sealant.

9. The processing technology of an integrated radiator chassis according to claim 1, characterized in that: The specific steps of step eight are as follows: use a coordinate measuring machine to detect key dimensions, conduct thermal simulation tests to detect the thermal resistance of the integrated heat dissipation module, perform CNC micro-correction on products with out-of-tolerance dimensions, and ensure the compatibility of the hardware mounting position with the heat spreader and fins.

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