Cooling Block Assembly to Prevent Weld-Induced Fluid Path Warping

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Solution Overview

Problem

Laser welding during the manufacturing of cooling blocks can cause deformation of the base and cover, leading to short circuits in the fluid pathway and degradation of performance.

Innovation Solution

A mechanical connection is established between the base and cover using inter-engaging components, such as protrusions and recesses, which are formed through milling, to reduce the likelihood of warping during welding, thereby maintaining the integrity of the fluid pathway.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If laser welding is used to join the base and cover, then the manufacturing efficiency and strength of the joint are improved, but the heat generated causes deformation of the base and cover leading to short circuits in the fluid pathway

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidgeometric integrity of fluid pathway

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The protrusions and recesses are designed and positioned before the welding process to establish a mechanical connection that pre-aligns the base and cover. This preliminary mechanical engagement ensures that the components are held in the correct geometric relationship prior to welding, preventing deformation-induced misalignment during the welding process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protrusions and recesses act as intermediary mechanical features that mediate between the base and cover during welding. These features serve as physical guides and constraints that maintain proper alignment and prevent warping from causing short circuits, while allowing the welding process to proceed with high efficiency.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If laser welding is used to join the base and cover, then the joint strength is improved, but the heat generated causes warping that short circuits the fluid pathway

Engineering Contradiction:

Improvejoint strengthVSAvoidfluid pathway integrity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The mechanical connection features (protrusions and recesses) are designed to engage before welding to establish proper alignment and prevent warping. This preliminary mechanical constraint ensures that even when heat is applied during welding, the base and cover remain properly positioned, maintaining both joint strength and fluid pathway integrity.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The protrusions and recesses serve as intermediary elements that protect the fluid pathway from warping-induced short circuits. These mechanical features act as physical barriers and alignment maintainers during the welding process, allowing strong joints to be formed without compromising the reliability of the fluid pathway.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If the base and cover are welded without mechanical connection features, then the manufacturing process is simpler, but deformation during welding causes short circuits and performance degradation

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidalignment precision during welding

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The protrusions and recesses are integrated directly into the base and cover structures during manufacturing, combining the alignment features with the structural components. This integration maintains manufacturing simplicity while ensuring proper alignment during welding, as the mechanical connection features are formed as part of the original components rather than being added separately.

Inventive Principle:

Principle #5Merging (Combining)

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 the risk of deformation and short circuits, ensuring a secure and efficient fluid pathway, thus enhancing the performance and reliability of the cooling block.

Implementation Method 1

The inter-engaging components of the base and the cover may comprise at least one protrusion associated with the base and at least one recess, configured to house at least a free end portion of the at least one protrusion, associated with the cover

Methodology Applied

Scientific EffectMechanical Fastener: Mechanical Fastener

Implementation Method 2

During the laser welding process, a large amount of heat is generated which often leads to deformation of the geometry of the base and/or the cover of the cooling block

Methodology Applied

Scientific EffectLaser Beam Welding: Laser Beam Welding

Data Source

PatentUS20250247999A1Cooling block for cooling a heat-generating electronic component

Publication Date: 2025.07.31 OVH

AI summary

A method for making a cooling block for cooling a heat-generating electronic component. The method includes providing a base defining an open passage and a protrusion and providing a cover positionable on the base to close the open passage forming a fluid conduit. The cover has an underside defining a recess which receives at least a free end of the protrusion. The method includes positioning the cover on the base such that at least the free end of the protrusion is received in the recess and the open passage is closed to form the fluid conduit and welding an outer side of the cover, along a weld path which includes at least a portion on the cover above the recess. A cooling block made by the method.