Aluminum Cooling Pipe Structure to Prevent Casting Misalignment

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Solution Overview

Problem

Existing methods for manufacturing cooling modules for heating elements using aluminum alloys face challenges such as deformation and misalignment of cooling pipes due to high pressure from molten metal, and the low strength of aluminum alloys makes it difficult to use insert injection molding effectively.

Innovation Solution

The solution involves casting products for cooling heating elements with a body made of a metal material and a cooling pipe made of an aluminum alloy, where the cooling pipe is designed with a thicker first pipe thickness in one direction and a thinner second pipe thickness in a perpendicular direction. This design, combined with a specific mold configuration and molten metal injection process, prevents deformation and misalignment of the cooling pipe during manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If aluminum alloy is used for cooling pipe to provide excellent cooling performance, then thermal conductivity is improved, but strength deteriorates making it difficult to manufacture using insert injection molding

Engineering Contradiction:

Improvecooling performanceVSAvoidstrength

Core Design Contradiction:

TemperatureVSStrength

Solution Approach 1:

The patent uses aluminum alloy material that combines high thermal conductivity with sufficient strength by optimizing the alloy composition and pipe wall thickness distribution, creating a composite-like performance within a single material system that resolves the contradiction between cooling performance and manufacturing feasibility

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent changes the pipe wall thickness parameters by making the first pipe thickness greater than the second pipe thickness, and optimizes the aluminum alloy composition parameters to achieve both excellent thermal conductivity and sufficient strength for insert injection molding manufacturing

Inventive Principle:

Principle #35Parameter changes

2Productivity

If insert injection molding method is used to manufacture cooling module, then manufacturing efficiency is improved, but cooling pipe deformation and misalignment occur due to high pressure from molten metal

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidcooling pipe position accuracy

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent performs preliminary actions by pre-positioning the cooling pipe in the mold cavity with precise locating structures before injection, and pre-designing the pipe thickness distribution to anticipate and counteract the high pressure effects during molten metal injection, thereby preventing deformation and misalignment

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent applies preliminary anti-action by designing the cooling pipe with asymmetric thickness distribution (first pipe thickness greater than second pipe thickness) and positioning structures that counteract the expected high pressure forces from molten metal injection, preventing deformation and maintaining position accuracy

Inventive Principle:

Principle #9Preliminary anti-action

3Strength

If cooling pipe is designed with asymmetric thickness (first pipe thickness greater than second pipe thickness), then resistance to molten metal pressure is improved, but manufacturing complexity increases

Engineering Contradiction:

Improveresistance to pressureVSAvoidpipe structure complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The patent applies local quality by making the first pipe thickness greater than the second pipe thickness at specific locations where high pressure from molten metal injection occurs, rather than uniformly increasing thickness throughout, thereby providing targeted strength enhancement while minimizing overall structural complexity

Inventive Principle:

Principle #3Local quality

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 enhances cooling efficiency by preventing deformation and misalignment of the cooling pipe, ensuring effective heat dissipation and maintaining the structural integrity of the aluminum alloy components.

Implementation Method 1

a cooling pipe providing a path through which a cooling fluid flows

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20250033111A1Casting products for cooling heating elements and method of manufacturing the same

Publication Date: 2025.01.30 NEDEC

AI summary

Provided are casting products for cooling heating elements, the casting products including: a body made of a metal material; and a cooling pipe providing a path through which a cooling fluid flows, and being made of an aluminum alloy material, wherein the body includes a plate-shaped plate portion, protrusion extensions protruding from the plate portion and extending along the cooling pipe so that at least part of the cooling pipe is fully buried, and a cooling pin structure formed integrally with the plate portion, and the cooling pipe is formed in such a way that a first pipe thickness of the cooling pipe having a cross-sectional shape in a first direction is greater than a second pipe thickness in a second direction perpendicular to the first direction, and the first direction is in parallel to the plate portion, and the second direction is a thickness direction of the plate portion.