Thermal Module Assembly with Copper Embedding for Secure Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional thermal module assembling structures face challenges in welding aluminum heat dissipation components due to oxidation, eutectic formation, and environmental pollution from chemical nickel plating, leading to weak connections and environmental harm.
Innovation Solution
The use of a copper embedding layer replaces chemical nickel plating, enhancing the connection between aluminum and copper components by ensuring secure welding without environmental pollution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If aluminum material is used to replace copper material, then weight and material cost are reduced, but welding difficulty increases due to oxidation and eutectic formation
Solution Approach 1:
A nickel plating layer is applied as an intermediary between the aluminum base seat and copper heat pipe. This nickel layer prevents direct contact between aluminum and copper, avoiding eutectic formation and oxidation issues during welding. The nickel plating serves as a mediator that enables reliable welding while maintaining the lightweight aluminum structure.
2Ease of manufacture
If electroless nickel plating is used to modify aluminum surface, then welding capability is improved, but environmental pollution and waste treatment complexity increase
Solution Approach 1:
The harmful phosphorus-containing plating solution and waste treatment processes are extracted and removed from the manufacturing system. The invention replaces the environmentally harmful electroless nickel plating with a mechanical embedding approach using copper particles and adhesive, eliminating yellow phosphorus waste and its associated environmental pollution while maintaining surface modification functionality.
3Device complexity
If copper and aluminum are directly welded, then manufacturing process is simplified, but welding quality deteriorates due to fissure and pore formation
Solution Approach 1:
The aluminum base seat surface is preliminarily prepared by embedding copper particles and applying adhesive before the actual welding process. This preliminary action creates a modified surface that prevents eutectic formation and oxidation during welding, ensuring high welding quality without requiring complex welding procedures or post-welding treatments.
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
The copper embedding layer facilitates secure welding of aluminum and copper components, reducing weight and cost while eliminating environmental pollution from chemical nickel plating.
Implementation Method 1
The copper base seat then transfers the absorbed heat to the heat pipe for speeding heat conduction
Implementation Method 2
A welding material layer is disposed between the copper embedding layer and the copper heat pipe
Data Source
AI summary
A thermal module assembling structure includes an aluminum base seat which has a heat absorption side, a heat conduction side and a connection section. The connection section is selectively disposed on the heat absorption side, the heat conduction side or embedded in the aluminum base seat (between the heat absorption side and the heat conduction side). The connection section is correspondingly connected with at least one copper heat pipe. A copper embedding layer is disposed on a portion of the connection section, which portion is in contact and connection with the copper heat pipe. A welding material layer is disposed between the copper embedding layer and the copper heat pipe, whereby the aluminum base seat and the copper heat pipe can be more securely connected with each other. The conventional chemical nickel plating is replaced with the copper embedding layer so as to improve the problem of environmental pollution, etc.