Additive Manufactured Flow-Through Heat Sink with Wetted Coupling
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Solution Overview
Problem
Conventional heat sinks with nonmetal matrix materials face challenges in achieving efficient thermal conductivity due to the use of adhesives or bonding agents, which create weak structural and thermally resistive joints when joined with metal thermal interface sheets, leading to reduced heat transfer efficiency.
Innovation Solution
The use of additive manufacturing processes like direct metal laser sintering, selective laser melting, or selective laser sintering to form a flow-through heat sink system with a wetted coupling between a graphite matrix and the enclosure, eliminating the need for adhesives and creating a direct, efficient heat conduction path without thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives or bonding agents are used to join nonmetal matrix materials with metal thermal interface sheets, then structural integrity is improved, but thermal conductivity deteriorates due to thermal resistance at the joint
Solution Approach 1:
The patent removes the adhesive or bonding agent from the joint between the nonmetal matrix material and metal thermal interface sheet. By eliminating this intermediate layer, the source of thermal resistance is removed while the additive manufacturing process directly bonds the materials together, maintaining structural integrity without compromising heat transfer efficiency.
Solution Approach 2:
The patent employs asymmetric material selection and processing, using additive manufacturing to create a direct metallurgical bond between dissimilar materials (metal and nonmetal matrix) with different thermal and mechanical properties. This asymmetric approach allows each material to contribute its optimal properties without the thermal penalty of symmetric adhesive bonding.
2Ease of manufacture
If conventional manufacturing methods are used to join heat sink components, then ease of manufacture is improved, but heat transfer efficiency deteriorates due to intervening adhesives
Solution Approach 1:
The patent merges the manufacturing process with the bonding process by using additive manufacturing to directly create the joint between components. This eliminates the need for separate adhesive application and curing steps, maintaining manufacturing simplicity while achieving direct thermal contact without intervening layers.
Solution Approach 2:
The patent replaces the chemical bonding mechanism (adhesives) with a thermal-field-based additive manufacturing process that directly fuses materials together. This substitution eliminates the thermal resistance inherent in adhesive bonds while maintaining the ease of manufacturing through automated layer-by-layer construction.
3Ease of operation
If adhesives are used to couple the enclosure to the conductive matrix, then ease of assembly is improved, but thermal conductivity deteriorates due to thermal resistance
Solution Approach 1:
The patent removes the adhesive layer from the coupling interface between the enclosure and conductive matrix. The additive manufacturing process directly forms this joint during production, eliminating the need for separate assembly steps with adhesives and simultaneously removing the source of thermal resistance.
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 enhances thermal conductivity and structural integrity by forming a glueless, bondless coupling, improving heat transfer characteristics and mitigating thermal expansion differences, resulting in a more efficient heat sink system compared to traditional methods.
Implementation Method 1
The additive manufacturing process comprises at least one of direct metal laser sintering, selective laser melting, or selective laser sintering
Implementation Method 2
The additive manufacturing process comprises at least one of direct metal laser sintering, selective laser melting, or selective laser sintering
Implementation Method 3
A wetted coupling may be formed between an interface between the conductive matrix and a surface of the enclosure in response to the additive manufacturing process occurring
Implementation Method 4
The flow of heat from a heat sink surface to the conductive matrix is direct through the enclosure to the conductive matrix
Implementation Method 5
Fourier's law states that the rate of heat flow, dQ/dt, through a homogeneous solid is directly proportional to the area, A, of the section at right angles to the direction of heat flow, and to the temperature difference along the path of heat flow, dT/dx
Implementation Method 6
A phase change material is added to the internal cavity via the port
Data Source
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AI summary
A system including a flow-through heat sink is depicted. A flow-through heat sink may include an enclosure (150;250) housing a nonmetal matrix composite. At least one surface of the enclosure (150;250) may be in contact and/or close proximity to a heat source. The enclosure (150;250) may be formed through an additive manufacturing process.