Additive Manufactured PCM Heat Sink Monolithic Design
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Solution Overview
Problem
Conventional phase change material heat sinks require expensive and potentially leak-prone vacuum brazing for sealing, which limits their production efficiency and robustness, and restricts design complexity.
Innovation Solution
The use of additive manufacturing to integrate the lower shell, upper shell, and internal matrix as a single component, eliminating the need for vacuum brazing and allowing for complex designs that optimize heat transfer and phase change material volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum brazing is used to seal the heat sink components, then the heat sink can contain the phase change material, but the production cost increases and potential leak paths and fatigue failure points are created
Solution Approach 1:
The patent merges the lower shell, upper shell, and internal matrix into a single integrated component formed by additive manufacturing. This eliminates the need for separate sealing operations (vacuum brazing) while maintaining the containment function, thereby reducing production cost and eliminating potential leak paths at joints.
Solution Approach 2:
The patent extracts the sealing function from the assembly process and integrates it into the additive manufacturing process itself. The sealed cavity is created directly during fabrication, removing the need for post-assembly sealing operations and their associated costs and reliability risks.
2Strength
If vacuum brazing is used to assemble the heat sink components, then the structure can be formed, but production time increases and potential fatigue failure points are created
Solution Approach 1:
The patent combines multiple components (lower shell, upper shell, internal matrix) into a single monolithic structure fabricated by additive manufacturing. This eliminates the time-consuming vacuum brazing process while maintaining structural integrity through the continuous material deposition inherent in additive manufacturing.
Solution Approach 2:
The patent performs the structural formation and sealing functions simultaneously during the additive manufacturing process, rather than sequentially. The sealed cavity structure is created as part of the primary fabrication process, eliminating subsequent assembly steps and reducing total production time.
3Device complexity
If conventional manufacturing techniques are used, then the heat sink structure can be formed, but design complexity is restricted
Solution Approach 1:
The patent changes the manufacturing approach from conventional subtractive or assembly-based methods to additive manufacturing. This parameter change enables complex geometries (such as optimized heat transfer pathways and integrated cavity structures) that would be difficult or impossible to achieve with traditional manufacturing techniques.
Solution Approach 2:
The patent utilizes the three-dimensional capabilities of additive manufacturing to create complex internal structures and optimized geometries that cannot be achieved with conventional two-dimensional or sequential assembly methods. This includes optimized heat transfer surfaces and integrated cavity formations.
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 reduces production costs and time, enhances robustness, and enables customizable, complex designs for efficient heat management, making the heat sink more suitable for various thermal applications.
Implementation Method 1
Phase change material heat sinks are capable of increasing thermal capacitance per volume/mass
Implementation Method 2
Phase change material (PCM) heat sinks are capable of increasing thermal capacitance per volume/mass
Data Source
AI summary
A heat sink is provided that includes a lower shell, an upper shell and an internal matrix. The lower shell, the upper shell and the internal matrix are formed as a single component using additive manufacturing techniques. The internal matrix includes a space that is configured to receive a phase change material.