Extruded Heat Sink Module With Integrated Coolant Flow Paths
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Solution Overview
Problem
Existing extruded heat sinks for secondary batteries require separate pipes for flow path formation, occupying space and limiting structural rigidity, while brazing heat sinks suffer from material degradation and complex flow path designs.
Innovation Solution
A heat sink assembly with integrally molded ribs forming a continuum by extrusion molding, featuring internal flow paths and communication ports, and sealed ends to eliminate the need for separate pipes, enhancing structural rigidity and simplifying flow path configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If brazing heat sinks are used to achieve high degree of freedom in flow path design, then flow path design flexibility is improved, but structural rigidity deteriorates due to material degradation
Solution Approach 1:
The heat sink is divided into multiple individual heat sink units, each with integrated flow paths formed by extrusion molding. This segmentation allows each unit to maintain structural rigidity while the collection of units provides flow path design flexibility through their arrangement and communication ports.
Solution Approach 2:
The flow path structure is merged directly into the heat sink body through extrusion molding, eliminating the need for separate brazed components. This integration maintains structural rigidity while achieving the desired flow path configuration within each heat sink unit.
2Strength
If extruded heat sinks are used to achieve structural rigidity, then structural rigidity is improved, but flow path design is limited to straight paths requiring multiple ports and pipes, increasing device complexity
Solution Approach 1:
The flow path design utilizes the depth dimension of the heat sink by forming ribs that extend partially through the thickness, creating internal channels that provide curved and multi-directional flow paths while maintaining the extruded structure's rigidity and reducing the need for additional external pipes.
Solution Approach 2:
Multiple flow paths are nested within the heat sink structure by arranging ribs in specific patterns, allowing complex coolant circulation within the rigid extruded body without requiring additional external piping components.
3Adaptability or versatility
If multiple separate pipes are used for flow path formation in extruded heat sinks, then flow path configuration is achieved, but space occupation increases and structural rigidity is compromised
Solution Approach 1:
The flow path structure is merged directly into the heat sink body through extrusion molding, eliminating the need for separate brazed components. This integration maintains structural rigidity while achieving the desired flow path configuration within each heat sink unit.
4Adaptability or versatility
If brazing is used to form flow paths, then flow path design freedom is improved, but reliability deteriorates due to material degradation
Solution Approach 1:
The patent uses extrusion molding to create disposable or replaceable heat sink units with integrated flow paths, avoiding the reliability issues of brazing. Each unit is manufactured as a complete, reliable component that can be replaced if needed, eliminating the material degradation problem associated with brazing joints.
Solution Approach 2:
The manufacturing method is changed from brazing to extrusion molding, fundamentally altering the process parameters to eliminate thermal cycling and material degradation. This parameter change maintains flow path design freedom while significantly improving reliability.
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 assembly occupies less space, improves differential pressure, and expands heat dissipation area by reducing components and optimizing coolant flow, maintaining structural integrity and efficiency.
Implementation Method 1
a plurality of heat sinks having a plurality of ribs integrally molded therein along a length direction by extrusion molding
Implementation Method 2
performs a cooling function by absorbing heat generated inside the pack with a coolant and releasing it to the outside
Data Source
AI summary
A heat sink assembly including a plurality of heat sinks having a plurality of ribs integrally molded along an internal length direction by extrusion molding, the spaces between the ribs forming a flow path through which a coolant flows, the first and second surfaces at both ends of the length direction being open, and the plurality of heat sinks having communication ports on one side wall adjacent to the first surface and/or the second surface is provided The plurality of heat sinks are integrally formed with the side walls forming bonding surfaces to match the communication ports and forming a heat sink module. The overall flow path of the heat sink module is fluidly connected by a communication port. The ribs of the heat sink having a length such that both ends are spaced apart from the first and second surfaces by a predetermined distance, and the open first and second surfaces of both ends of the heat sink module are closed by a pack frame.