3D-Printed Cold Plate Structure to Eliminate Channel Leakage
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Solution Overview
Problem
Existing cold plate systems for electronics are expensive, prone to leakage, and have complex internal geometries that are costly and time-consuming to manufacture, often requiring welding, brazing, or mechanical fastening, which complicates the manufacturing process and may lead to failures in critical thermal management systems.
Innovation Solution
The development of additively manufactured heat transfer devices with a single unitary structure that includes an enclosure portion with inner channels for coolant flow, eliminating the need for secondary supports and reducing the risk of leakage and manufacturing complexity, by using methods like Direct Metal Laser Sintering or metal fused deposition modeling to create complex geometries without internal secondary supports.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional manufacturing methods (welding, brazing, mechanical fastening) are used to form channels, then channels can be created, but manufacture becomes complicated and more prone to failure
Solution Approach 1:
The patent merges the channel structure with the housing into a single unitary component formed by additive manufacturing. The channels are formed as integral void spaces within the housing material, eliminating the need for separate channel components and their associated joining operations (welding, brazing, or mechanical fastening). This integration directly resolves the technical contradiction by removing multiple potential failure points from joins while simplifying the manufacturing process to a single additive manufacturing operation.
Solution Approach 2:
The additive manufacturing process enables segmentation of the housing into functional zones (channels, walls, supports) at the digital design stage, which are then manufactured as a unified structure. The channel geometry can be independently optimized and defined through CAD modeling before manufacturing, allowing complex internal geometries to be created without physical segmentation or assembly steps.
2Shape
If complex internal geometries are manufactured traditionally, then channels can be formed, but manufacturing time and cost increase significantly
Solution Approach 1:
The patent replaces traditional mechanical manufacturing methods (milling, drilling, routing) with additive manufacturing technology. This substitution enables the direct formation of complex three-dimensional channel geometries that would be time-consuming or impossible to create with conventional subtractive or formative processes. The additive process builds channels layer-by-layer according to digital models, dramatically reducing manufacturing time and cost for complex geometries.
Solution Approach 2:
The invention changes the fundamental manufacturing parameter from subtractive removal of material to additive deposition of material. This parameter change allows complex internal geometries to be manufactured efficiently, as the additive process can create any geometry defined in the digital model without the time and cost penalties associated with traditional methods. The manufacturing efficiency scales favorably with geometric complexity.
3Adaptability or versatility
If multiple parts are assembled to form the heat transfer device, then flexibility in design is improved, but leakage risk and manufacturing cost increase
Solution Approach 1:
The patent combines the housing and internal channel structures into a single unitary component manufactured by additive manufacturing. This merger eliminates all interfaces, joints, and seals between parts, thereby eliminating the primary sources of leakage in traditional assembled cold plates. The design flexibility is maintained through the ability to digitally configure channel geometries and housing features before manufacturing, without requiring physical assembly of multiple components.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in a more reliable, cost-effective, and efficient thermal management solution with reduced manufacturing time and complexity, as well as improved operational reliability by eliminating failure modes related to part connections and allowing for repeatable geometry in mass production.
Implementation Method 1
methods like Direct Metal Laser Sintering or metal fused deposition modeling
Implementation Method 2
Direct Metal Laser Sintering
Implementation Method 3
The channel may be configured to conduct heat from the heat transfer face to a fluid
Implementation Method 4
configured to direct a flow of coolant fluid through an outer wall of the enclosure portion into the inner channel
Data Source
AI summary
An additively manufactured heat transfer device is disclosed, including an enclosure portion with outer walls. The outer walls contain an inner channel configured to direct a flow of coolant fluid. The heat transfer device further includes a fluid intake port and a fluid outtake port, each connected to the first inner channel. The fluid intake port is configured to direct a flow of coolant fluid through an outer wall of the enclosure portion into the inner channel, and the fluid outtake port is configured to direct a flow of coolant fluid through an outer wall of the enclosure portion out of the inner channel. The inner channel is defined by internal walls, and the enclosure portion and the internal walls form a single additively manufactured unit.