Three-Layer Bubble Sheet Cold Plate for Flexible Coolant Channels
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Solution Overview
Problem
Existing methods for manufacturing cold plates, such as extrusion and brazing, are costly, time-consuming, and limited in shape and size, necessitating an alternative approach for producing efficient and cost-effective cooling solutions.
Innovation Solution
A three-layered bubble sheet cooling plate is manufactured by stacking three metal sheets, welding their edges, and bonding the top and bottom sheets to a thinner middle sheet at specific locations, followed by the introduction of a pressurized medium to deform the middle sheet and create channels for coolant flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If extrusion process is used to manufacture cold plate, then structural strength is improved, but manufacturing cost and production time increase
Solution Approach 1:
The cold plate is divided into multiple separate metal sheets (first, second, and third sheets) that are stacked and bonded together. This segmentation allows each sheet to be manufactured independently using simple processes, then assembled quickly, resolving the contradiction between structural strength and manufacturing efficiency.
2Manufacturing precision
If brazing process is used to manufacture cold plate, then manufacturing precision is improved, but production cost and time increase
Solution Approach 1:
The brazing process (thermal/chemical joining) is replaced with mechanical bonding methods such as welding, adhesive bonding, or friction stir welding. This substitution maintains manufacturing precision while dramatically reducing production time and cost, as these bonding methods are faster and require less complex fixtures.
3Stability of the object's composition
If extrusion process is used to manufacture cold plate, then structural integrity is improved, but design flexibility worsens
Solution Approach 1:
By segmenting the cold plate into multiple stackable sheets, the design becomes highly flexible. Different sheet configurations, bonding patterns, and channel layouts can be created by arranging sheets in various sequences and bonding them at different locations, maintaining structural integrity while enabling custom designs.
Solution Approach 2:
The cold plate design transitions from a single extruded dimension to a multi-layer stacked structure. This adds dimensional flexibility, allowing channels to be created in multiple planes and configurations by stacking sheets with different channel patterns, thereby improving design versatility.
4Strength
If brazing process is used to manufacture cold plate, then bonding strength is improved, but manufacturing complexity increases
Solution Approach 1:
Complex brazing operations are replaced with simpler mechanical bonding methods. Welding, adhesive bonding, or friction stir welding require fewer fixtures, less precise alignment, and shorter cycle times, reducing manufacturing complexity while maintaining adequate bonding strength for the application.
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 reduces production costs and time while allowing for flexible design and efficient heat transfer, as the process avoids expensive tooling and complex manufacturing steps, and the resulting cold plate can be easily expanded to create channels for coolant flow.
Implementation Method 1
A pressurized medium is supplied between the top one of the metal sheets and the bottom one of the metal sheets to separate the top one of the metal sheets from the bottom one of the metal sheets and deform the middle one of the metal sheets
Implementation Method 2
An edge of the three metal sheets are welded or otherwise secured together. The top one of the metal sheets is bonded to a middle one of the metal sheets at a plurality of first locations and a bottom one of the metal sheets is bonded to the middle one of the metal sheets
Data Source
AI summary
A method of making a cold plate includes stacking three aluminum sheets on top of each other while each of the three aluminum sheets is generally flat. An edge of the three aluminum sheets are secured together. A top one of the aluminum sheets is welded to a middle one of the aluminum sheets at a plurality of first locations and a bottom one of the aluminum sheets is welded to the middle one of the aluminum sheets at a plurality of second locations different than the plurality of first locations. A pressurized medium is supplied between the top one of the aluminum sheets and the bottom one of the aluminum sheets to separate the top one of the aluminum sheets from the bottom one of the aluminum sheets and deform the middle one of the aluminum sheets.