Additively Manufactured Cooling Fins for Gradient Thermal Conductivity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooling systems for heat-dissipating surfaces, such as those in radar and electronic systems, face challenges in managing temperature gradients, leading to unintentional beam steering and calibration difficulties due to complex coolant flow requirements and inefficient heat transfer.
Innovation Solution
The use of additive manufacturing to create a manifold structure with fins that have varying geometries and material properties along the cooling channel, providing a gradient convection coefficient and thermal conductivity, which reduces temperature rise and maintains a linear heat transfer rate across the heat-dissipating surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional cooling systems with uniform fins are used, then the structure is simple to manufacture, but the temperature gradient across the heat-dissipating surface is high causing beam steering and calibration issues
Solution Approach 1:
The patent applies local quality by varying the fin characteristics (geometry, material composition, spacing) at different locations along the cooling channel. Specifically, fins near the inlet have different properties than fins near the outlet, creating a gradient that optimizes heat transfer at each location. This resolves the contradiction by achieving uniform temperature distribution (improving temperature control) while using localized variations rather than complete system redesign (managing complexity).
Solution Approach 2:
The patent implements parameter changes by systematically varying fin parameters including geometry (height, thickness, spacing), material composition (gradients from aluminum to copper), and arrangement density along the cooling channel length. These parameter variations create a gradient heat transfer coefficient that compensates for the natural temperature drop along the channel, achieving uniform cooling across the heat-dissipating surface while using manufacturable gradient structures.
2Temperature
If coolant flow rate is increased to reduce temperature gradient, then heat transfer improves, but the system complexity and calibration difficulty increase
Solution Approach 1:
The patent applies self-service by designing a passive gradient fin structure that automatically compensates for temperature variations along the cooling channel without requiring active flow control or calibration. The gradient in fin properties (from inlet to outlet) creates a corresponding gradient in heat transfer coefficients that naturally balances the temperature distribution. This resolves the contradiction by achieving temperature uniformity through self-regulating geometry rather than complex active control systems.
3Productivity
If additive manufacturing is used to create gradient fin structures, then heat transfer efficiency improves, but manufacturing complexity increases
Solution Approach 1:
The patent applies composite materials by creating fins with graded material composition along their length or across different fin positions. Specifically, the fins transition from aluminum-based materials at the inlet to copper-based materials at the outlet, or use intermediate alloy compositions. This gradient material distribution optimizes heat transfer efficiency (improving productivity) while additive manufacturing enables this complex material distribution in a single integrated structure (managing manufacturing complexity compared to traditional assembly methods).
Solution Approach 2:
The patent applies segmentation by dividing the cooling channel into multiple zones with distinct fin characteristics. The channel is segmented into inlet, middle, and outlet sections, each with fins optimized for their specific thermal conditions. This segmentation allows additive manufacturing to create the gradient structure efficiently (improving heat transfer) while maintaining manufacturing feasibility through systematic zonation rather than continuous complex 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
This approach effectively minimizes temperature gradients and ensures a consistent heat transfer rate, enhancing the performance and calibration of electronic devices by optimizing heat dissipation through a structured and material gradient design.
Implementation Method 1
The plurality of fins include a material transition area in which the plurality of fins gradually transitions from a first material to second material... the plurality of fins are configured to provide a gradient thermal conductivity across the length of the heat-dissipating surface
Implementation Method 2
at least one cooling channel that is connected between the inlet fluid passage and the outlet fluid passage and extends along a length of the heat-dissipating surface
Data Source
Figure 1~2
Figure 3~7
Figure 8~11
AI summary
A manifold structure is provided to cool a heat-dissipating surface and includes an inlet fluid passage, an outlet fluid passage, and at least one cooling channel that is connected between the inlet fluid passage and the outlet fluid passage and extends along a length of the heat-dissipating surface. Additively manufactured fins are arranged in the cooling channel. The fins are configured to provide a geometry transition area between fins having a first geometry and fins having a second geometry, and a material transition area between fins formed of a first material and fins formed of a second material. The manifold structure is configured to provide a gradient convection coefficient by way of the geometry transition area and a gradient thermal conductivity by way of the material transition area across the length of the heat-dissipating surface.