Thermally Conductive Foam Core Heat Spreader for Weight Reduction

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Solution Overview

Problem

Conventional heat spreaders in large telecommunication devices, such as remote radio units, are excessively heavy due to their solid structure, contributing significantly to the overall weight and hindering weight reduction while maintaining cooling efficiency.

Innovation Solution

A heat spreader with a hollow core filled with thermally conductive foam, which reduces weight by 30%-70% compared to solid structures, maintaining structural rigidity and using materials like aluminum, copper, or titanium alloys for enhanced thermal conductivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If a solid structure heat spreader is used, then thermal conductivity is maintained, but weight increases significantly

Engineering Contradiction:

Improveheat spreader weightVSAvoidstructural rigidity

Core Design Contradiction:

Weight of moving objectVSStrength

Solution Approach 1:

The patent applies porous foam materials (metal foam, ceramic foam, or polymer foam) as the core structure of the heat spreader. These porous materials provide a lightweight alternative to solid structures while maintaining adequate structural rigidity and thermal conductivity through their interconnected pore networks that allow heat transfer pathways.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent employs composite material construction by combining different materials in the heat spreader structure - such as metal foam cores with external metal cladding, or ceramic foam with protective coatings. This composite approach optimizes both weight reduction and structural strength by leveraging the advantages of each material.

Inventive Principle:

Principle #40Composite materials

2Weight of moving object

If a hollow core structure is used, then weight is reduced, but thermal conductivity decreases

Engineering Contradiction:

Improveheat spreader weightVSAvoidthermal conductivity

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The porous foam material fills the hollow core and provides continuous thermal conduction pathways through its interconnected cellular structure. The pores are filled with conductive material or configured to allow heat transfer, maintaining thermal conductivity while keeping the structure lightweight.

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The patent applies different material properties to different regions of the heat spreader. The hollow core regions are filled with foam materials optimized for weight reduction, while external surfaces and critical heat transfer zones use materials with higher thermal conductivity to ensure adequate heat dissipation performance.

Inventive Principle:

Principle #3Local quality

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 solution effectively reduces the weight of the heat spreader by 30%-70% while maintaining structural integrity and thermal conductivity, making it more efficient and lighter than conventional heat spreaders.

Implementation Method 1

a foam core located in the hollow core

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9813082B2Heat spreader with thermally coductive foam core

Publication Date: 2017.11.07 FUTUREWEI TECHNOLOGIES INC

AI summary

A heat spreader and a method for making a heat spreader are disclosed. In an embodiment the heat spreader includes an enclosure with a hollow core and a foam core located in the hollow core.