Additively Manufactured Wick Unit Cells for Thermal Management
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Solution Overview
Problem
Conventional thermal management devices for computing devices face challenges in efficiently managing heat due to limitations in capillary wicking and structural support, particularly in thin form factors where pressure differentials restrict evaporative and capillary action, leading to non-uniform heat rejection and potential hot spots.
Innovation Solution
The integration of additively manufactured wick and support unit cells with struts forming a shell structure within a housing, allowing for both capillary wicking and structural support in a single, unitary structure, enhancing fluid transport and maintaining vapor space while reducing weight and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional wicking structures are used in thin form factors, then device size is reduced, but heat rejection uniformity deteriorates due to pressure differential restrictions on capillary action
Solution Approach 1:
The patent combines the wicking structure and support structure into a single integrated unitary structure manufactured via additive manufacturing. This integration allows the wicking channels to be precisely formed within the support structure, ensuring uniform capillary action and heat rejection across the entire surface even in thin form factors where pressure differentials would otherwise restrict fluid flow.
Solution Approach 2:
The patent utilizes additive manufacturing to create complex internal geometries with specific channel sizes, shapes, and distributions that optimize capillary action. By controlling the physical parameters of the wicking channels (size, shape, distribution) at the micro-scale, the system achieves uniform heat rejection while maintaining a thin overall form factor.
2Reliability
If separate wicking and support structures are used, then functional performance is maintained, but device weight and complexity increase
Solution Approach 1:
The patent merges the wicking function and support function into a single unitary structure. The additive manufacturing process enables both functions to be achieved through one integrated component rather than requiring separate wicking material and support framework, thereby reducing overall weight and structural complexity while maintaining both capillary wicking performance and mechanical support.
Solution Approach 2:
The integrated structure serves multiple functions simultaneously: it provides mechanical support for the vapor chamber, creates vapor space, and enables capillary wicking for fluid transport. This multi-functionality eliminates the need for separate components, reducing weight and simplifying the overall device architecture.
3Device complexity
If additive manufacturing is used for unit cells, then structural integration is improved, but manufacturing complexity increases
Solution Approach 1:
The patent employs additive manufacturing to create complex internal geometries that would be impossible or extremely difficult to achieve with conventional manufacturing methods. The process enables precise control over channel size, shape, and distribution, allowing the wicking and support structures to be integrated in ways that simplify the overall device architecture despite the advanced manufacturing technique required.
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 solution enables efficient, uniform heat rejection and structural integrity in thin form factors, reducing weight and maintaining effective thermal management by integrating wicking and support functions in a single structure, thus addressing the limitations of conventional devices.
Implementation Method 1
The wicking structure includes a plurality of additively manufactured wick unit cells... enabling efficient fluid transport
Implementation Method 2
The system includes a housing... a plurality of additively manufactured wick unit cells... a plurality of additively manufactured support unit cells... enabling efficient, uniform heat rejection
Data Source
AI summary
A wicking structure and/or support structure for thermal management is described. The wicking structure and/or structural support may include a plurality of additively manufactured wick unit cells. Each unit cell may include a plurality of struts that have a shell. A thermal management system that includes a wicking structure and/or a support structure is also described.