3D Vapor Chamber Assembly With Continuous Capillary Structure

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Solution Overview

Problem

The existing methods for forming three-dimensional vapor chambers are complex and limit the number of suppliers and types of air fins that can be used, restricting their effectiveness in dissipating heat from electronic components.

Innovation Solution

A method involving two separate parts, an evaporator and a condenser, connected by a capillary intermediate structure and hermetically sealed, allowing for the formation of a 3D-vapor chamber that can be easily manufactured and effectively dissipate heat, with the option to enhance cooling using freely designed air fins.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the vapor chamber is assembled directly in three-dimensional shape with capillary structure running from sides to top, then capillary structure continuity is ensured, but the manufacturing process becomes complex and limits the number of suppliers

Engineering Contradiction:

Improvecapillary structure continuityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The vapor chamber is divided into multiple separate components (base plate, side walls, capillary structures) that are manufactured independently and then assembled. This segmentation allows each component to be produced by different suppliers using standard processes, reducing manufacturing complexity while maintaining capillary continuity through precise joining interfaces.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Connecting elements or intermediate structures are introduced at the junctions between vapor chamber components. These intermediaries facilitate the connection of capillary structures from different parts, ensuring continuous liquid transport paths while simplifying the assembly process and allowing modular manufacturing.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If internal porous coated pillars are used to ensure structural strength and local distribution of liquid, then structural integrity is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvestructural strengthVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Porous materials are used in specific regions of the vapor chamber to provide both structural support and liquid distribution functions. These porous structures are integrated into the design to simultaneously achieve mechanical strength and capillary action, eliminating the need for separate reinforcing elements and simplifying manufacturing.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The structural support function and liquid distribution function are merged into a single integrated component design. The porous coated pillars serve dual purposes: providing mechanical strength to the vapor chamber structure and facilitating liquid distribution through their porous properties, thereby reducing the number of separate components needed.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If the standard assembly method is used, then capillary structure continuity is maintained, but the type of usable air fins is limited to low performance flat fins

Engineering Contradiction:

Improvecapillary structure continuityVSAvoidair fin design flexibility

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The vapor chamber is segmented into modular components that can be assembled in different configurations. This modularity allows various air fin designs to be attached to different surfaces without compromising capillary continuity, enabling the use of high-performance three-dimensional fin structures instead of limited flat fins.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The design transitions from two-dimensional flat fin configurations to three-dimensional fin structures by utilizing the vertical and lateral dimensions more effectively. The segmented vapor chamber architecture allows air fins to be positioned and oriented in multiple directions, enhancing heat dissipation performance while maintaining capillary structure integrity.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 method simplifies the manufacturing process, maintains capillary structure continuity, and allows for high-performance cooling with flexible air fin designs, effectively dissipating heat from electronic components.

Implementation Method 1

a capillary structure for guiding liquid water

Methodology Applied

Scientific EffectCapillary action: Capillary Action

Implementation Method 2

an evaporator and a condenser... water vapor which is present in the inner volume

Methodology Applied

Scientific EffectEvaporation: Evaporation

Implementation Method 3

a condenser... water vapor which is present in the inner volume may condense

Methodology Applied

Scientific EffectCondensation: Condensation

Data Source

PatentEP3715766B1Method of forming a 3d-vapor chamber

Publication Date: 2022.11.16 ABB (SCHWEIZ) AG

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AI summary

The invention relates to a method which is suited for manufacturing a 3D-vapor chamber (10) in a defined and efficient manner. Especially, the present method provides a solution for providing a vapor chamber (10) having an evaporator and a condenser made from a first part (12) and a second part (14), wherein continuity of internal structures is given which in turn provides an efficient working behaviour of the vapor chamber (10).