Cast Cooling Structure With Composite Pipe For Power Amplifier
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Solution Overview
Problem
Existing cooling structures face challenges with large size deformation or insufficient cooling performance due to low heat-resistant metal pipes, and drilling methods limit shape flexibility and increase size, leading to reduced cooling efficiency for heat-generating elements.
Innovation Solution
A cooling structure comprising a copper pipe with iron and copper plating layers, cast inside a thermally conductive aluminum plate, allowing for flexible shaping without increasing size and enhancing thermal conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a metal pipe with low heat resistance is used in a casting mold, then the manufacturing process is simpler and cost-effective, but the pipe may be deformed or melted due to prolonged exposure to high-temperature molten metal
Solution Approach 1:
The patent applies composite materials by coating the metal pipe with a heat-resistant material layer. The pipe consists of a base metal material providing thermal conductivity and structural framework, combined with a heat-resistant coating material that protects against molten metal temperatures. This composite structure allows the pipe to withstand high-temperature casting processes while maintaining structural integrity and enabling simpler manufacturing compared to using entirely heat-resistant alloy pipes.
2Reliability
If a stainless steel metal pipe with high heat resistance is used, then the pipe can withstand high-temperature molten metal, but the thermal conductivity decreases leading to insufficient cooling performance
Solution Approach 1:
The patent uses composite materials where the pipe base is made of high thermal conductivity metal (such as copper or aluminum alloy) and is coated with a heat-resistant material layer. This composite structure combines the advantages of both materials: the metal base provides excellent thermal conductivity for efficient cooling, while the heat-resistant coating protects the pipe from molten metal temperatures during casting, thus resolving the contradiction between heat resistance and cooling efficiency.
Solution Approach 2:
The patent applies local quality by differentiating the properties of different parts of the pipe structure. The inner base material is designed with high thermal conductivity for heat dissipation, while the outer coating layer is designed with high heat resistance for protection. Each layer performs its specific function locally, allowing the pipe to simultaneously achieve both efficient cooling and high-temperature resistance.
3Ease of manufacture
If a drilling method is used to create cooling water flow passageways, then the manufacturing process is straightforward, but the shape flexibility of passageways is reduced and coupling members are required increasing size
Solution Approach 1:
The patent applies preliminary action by pre-forming the cooling water flow passageways within the pipe structure before the pipe is installed in the casting mold. The passageways are created during pipe manufacturing using methods such as internal mandrels or 3D printing, allowing complex three-dimensional shapes to be achieved without requiring post-installation drilling or coupling members. This preliminary formation of passageways provides shape flexibility while maintaining manufacturing efficiency.
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 configuration increases shape flexibility of cooling water flow passageways while maintaining high cooling performance, preventing pipe deformation and improving heat dissipation for heat-generating elements without size increments.
Implementation Method 1
a first layer formed on an outer surface of the base material... the first layer is made of a second material having a heat resistance
Implementation Method 2
the base material is made of a first material being highly thermally conductive... the plate is made of a fourth material being highly thermally conductive
Implementation Method 3
a pipe that has a base material in which a cooling water flow passageway is formed... capable of exploiting cooling performance
Data Source
AI summary
A cooling structure according to the present invention is provided with: a base material formed with a cooling water flow passageway; a pipe which includes a first layer formed on an outer surface of the base material, and a second layer formed on the outside of the first layer; and a plate having the pipe cast therein. The base material is configured from a highly thermally conductive first material. The first layer is configured from a heat-resistant second material. The second layer is configured from a third material having high affinity with the second material. The plate is configured from a highly thermally conductive fourth material. The second material and the third material respectively have high affinity with the fourth material.