Friction Stir Welded Cooling Plate for Leak-Tight Coolant Sealing
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Solution Overview
Problem
Current cooling systems for high-voltage direct-current transmission systems face challenges in preventing coolant leakage and require additional members for sealing and stress management due to thermal expansion differences and vortex flow, which can lead to distortion and stress.
Innovation Solution
A cooling plate design featuring a coolant accommodation portion with a flow-path portion and a cover that seals using friction stir welding, eliminating the need for additional sealing members and minimizing thermal stress through shared material expansion coefficients and gas shielded brazing for vortex control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a conventional cooling plate is used, then the structure is simple, but the heat dissipation efficiency is insufficient and hot spots cannot be effectively cooled
Solution Approach 1:
The cooling plate incorporates variable thickness design where the thickness changes according to the heat generation distribution of the LED array. Regions with higher heat generation have greater thickness to provide enhanced heat dissipation capacity, while regions with lower heat generation have reduced thickness. This local differentiation of structural properties enables targeted cooling of hot spots without uniformly increasing the complexity of the entire cooling plate structure.
2Power
If the cooling plate thickness is increased to improve heat dissipation, then the heat dissipation capacity increases, but the volume and weight increase
Solution Approach 1:
Instead of uniformly increasing the thickness of the entire cooling plate, the invention applies variable thickness only in specific regions where heat generation is highest. The thickness distribution is optimized to provide sufficient heat dissipation capacity in hot spot areas while maintaining minimal thickness in regions with lower thermal loads, thereby avoiding unnecessary volume and weight increases.
Solution Approach 2:
The cooling plate is divided into multiple regions with different thickness characteristics based on the LED array layout and heat generation patterns. This segmentation allows each region to be optimized independently for its specific thermal requirements, achieving overall effective heat dissipation with minimized total material usage and volume.
3Reliability
If the cooling plate structure is optimized for heat dissipation, then the heat dissipation efficiency improves, but the manufacturing complexity increases
Solution Approach 1:
The invention optimizes the thickness parameter of the cooling plate to achieve variable thickness profiles that match heat generation patterns. By carefully selecting and adjusting thickness parameters within reasonable ranges, the design achieves improved heat dissipation efficiency while maintaining manufacturability through standard fabrication processes that can handle moderate thickness variations.
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 seals the coolant path, prevents leakage, and reduces thermal stress and distortion by using friction stir welding for coupling and gas shielded brazing for vortex control, ensuring stable operation without additional sealing members.
Implementation Method 1
cooling plate for a light emitting diode (LED) array... heat dissipation capacity... hot spots
Data Source
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AI summary
Disclosed are a cooling plate and a manufacturing method therefor. The cooling plate according to an embodiment of the present invention comprises a cooling cover and a cooling body which has a cooling fluid accommodation portion formed therein and to which the cooling cover is coupled. The cooling cover is coupled to the cooling body so as to seal the cooling fluid accommodation portion. The cooling cover and the cooling body are coupled through friction stir welding. Thus, the cooling fluid accommodation portion can be reliably sealed.