Multi-Channel Copper Tube Manufacturing with Water-Cooled Mandrel
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Solution Overview
Problem
Manufacturing multi-channel copper tubes is challenging due to difficulties in forming copper, which has superior heat transfer properties but is abrasive and causes wear on manufacturing equipment, limiting the production of copper tubes for applications like cooling electronic components.
Innovation Solution
A method and apparatus for manufacturing multi-channel copper tubes involve continuous casting of molten copper using a die set with a hollow portion and punches, where molten copper is fed through a feed passage to solidify, and the use of adjustable cooling to extend die set life, along with annealing and specific mandrel arrangements to reduce friction and wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If copper is used for multi-channel tube manufacturing, then heat transfer properties are improved, but wear on manufacturing equipment increases
Solution Approach 1:
The patent introduces a water-cooled mandrel as an intermediary component between the copper tube and the die set. The mandrel absorbs frictional heat and reduces direct contact wear on the die set by acting as a sacrificial intermediate surface that can be cooled and replaced more easily than the entire die set.
Solution Approach 2:
The patent applies water cooling to change the temperature parameter of the mandrel surface, creating a thermal gradient that reduces copper adhesion and friction. By maintaining the mandrel surface at a lower temperature, the copper tube can be drawn through with reduced friction and wear on the manufacturing equipment.
2Productivity
If continuous casting method is used, then productivity is improved, but manufacturing precision deteriorates due to difficulty in forming copper
Solution Approach 1:
The water-cooled mandrel serves as a mediator that enables continuous casting by providing a controlled surface for copper solidification. The mandrel's cooling effect allows the copper to solidify uniformly while being drawn through, maintaining dimensional precision despite the continuous high-speed manufacturing process.
Solution Approach 2:
The patent employs a dynamic drawing process where the mandrel and die set move continuously to draw the copper tube at controlled speeds. This dynamic approach allows the copper to be formed under controlled conditions while maintaining continuous production, balancing speed with precision through controlled deformation rates.
3Duration of action of stationary object
If die set is cooled to extend life, then duration of action of stationary object is improved, but temperature distribution becomes non-uniform
Solution Approach 1:
The patent applies localized cooling only to the mandrel surface that contacts the copper tube, rather than cooling the entire die set uniformly. This local quality approach extends the life of the high-wear mandrel area through targeted cooling while leaving other areas of the die set at optimal forming temperatures, maintaining temperature uniformity where needed.
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 enables the reliable and cost-effective production of multi-channel copper tubes with an equiaxed grain structure, reducing wear on equipment and maximizing die set life, while achieving the desired wall thickness and channel configuration.
Implementation Method 1
molten copper being supplied from the crucible to the space within the die set through the feed passage and solidifying as it passes through the hollow portion
Implementation Method 2
Cooling the hollow portion die may include feeding coolant into cooling bores which extend into the hollow portion die from its outlet end for part of its length
Implementation Method 3
supplying the molten copper from the crucible to the space within the die set by gravity
Data Source
AI summary
This manufacturing apparatus for a multi-channel tube having a plurality of parallel channels includes: a crucible; and a die set for forming the multi-channel tube from molten copper supplied from the crucible, the die set including: a hollow portion having an inner surface shaped like the profile of the multi-channel tube; punches which are inserted into the hollow portion from an inlet end of the hollow portion to define a space between the inner surface of the hollow portion and each of the punches; and a feed passage which is disposed between the crucible and the space, and configured to feed the molten copper from the crucible to the space, the molten copper being supplied from the crucible to the space within the die set through the feed passage to solidify as it passes through the hollow portion.