3D Vapor Chamber Assembly With Welded Heat Pipe Flanges

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Solution Overview

Problem

Existing three-dimensional vapor chamber structures face issues with loose connections due to welding materials like copper paste or tin paste, which can enter the accommodation chamber, affecting heat transfer and dissipating performance, and are prone to vibration-induced loosening during assembly and transport.

Innovation Solution

A three-dimensional vapor chamber assembly structure that uses electrical resistance welding to combine heat pipes with a housing plate, eliminating the need for welding materials inside the chamber, and incorporates a capillary structure and working fluid for stable assembly and enhanced heat transfer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If welding materials like copper paste or tin paste are used to combine heat pipes with the vapor chamber, then the heat guiding and heat dissipating performance is improved, but the welding materials may enter the accommodation chamber and block the transferring path of the internal working fluid

Engineering Contradiction:

Improveheat guiding and heat dissipating performanceVSAvoidwelding material entering accommodation chamber

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces a sealing ring as an intermediary component between the heat pipes and the vapor chamber housing. This sealing ring prevents welding materials from entering the accommodation chamber while still allowing effective heat transfer, thus resolving the contradiction between heat dissipation performance and prevention of harmful material intrusion.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If welding materials are used to assemble heat pipes and vapor chamber, then the connection strength is improved, but the assembly may become loosened due to vibrations during transporting process

Engineering Contradiction:

Improveassembling strengthVSAvoidassembly stability under vibration

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent replaces the traditional mechanical welding material-based connection with an electrical resistance welding operation that creates a direct metallurgical bond between the heat pipe flanges and the vapor chamber housing. This eliminates the need for separate welding materials and creates a more vibration-resistant connection.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If electrical resistance welding operation is used to combine heat pipes with housing plate, then the need for welding materials is eliminated and manufacturing is simplified, but the connection stability must be ensured without welding materials

Engineering Contradiction:

Improvemanufacturing procedure simplicityVSAvoidconnection stability

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent uses electrical resistance welding to create a direct metallurgical bond between the heat pipe flanges and the vapor chamber housing, eliminating the need for separate welding materials. This process simplifies manufacturing while ensuring connection stability through a strong, integrated joint that is resistant to vibration and loosening.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

Ensures stable assembly, prevents welding materials from entering the accommodation chamber, enhances heat conducting and dissipating performance, and simplifies manufacturing while ensuring smooth fluid transfer.

Implementation Method 1

each of the heat pipes is combined with the second housing plate via a welded layer on the flange and the recessed slot

Methodology Applied

Scientific EffectElectrical resistance welding: Welding

Implementation Method 2

a rapid heat guiding and heat dissipating performance is achieved via a phase change of gasifying and liquidizing

Methodology Applied

Scientific EffectPhase change of gasifying and liquidizing: Phase Change

Implementation Method 3

The working fluid is disposed in the accommodation chamber

Methodology Applied

Scientific EffectHeat transfer through working fluid: Convection

Data Source

PatentUS20260049771A1Three-dimensional vapor chamber assembly structure

Publication Date: 2026.02.19 TAIWAN MICROLOOPS CORP

AI summary

A three-dimensional vapor chamber assembly structure includes: a housing including a first housing plate and a second housing plate, an accommodation chamber is formed between the first housing plate and the second housing plate, the second housing plate has penetrated holes, and a recessed slot is respectively formed at an outer circumference of the penetrated holes; a plurality of heat pipes correspondingly disposed in the penetrated holes, the heat pipes has an open end, the open end has a flange, the flange is disposed in the recessed slot, the heat pipe is combined with the second housing plate via a welded layer on the flange and the recessed slot; a capillary structure disposed in the accommodation chamber and attached on the housing and a working fluid is disposed in the accommodation chamber. Accordingly, a welding material is prevented from entering the accommodation chamber.