Heat Dissipation Device With Mechanical Locking For Weld-Free Assembly

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Solution Overview

Problem

Current heat dissipation devices require welding to securely connect the mounting bracket to the thermal module, leading to potential misalignment, increased manufacturing costs, and environmental hazards.

Innovation Solution

A heat dissipation device design featuring a mounting bracket with retaining holes and a thermal module with engaging zones and locking portions, allowing for secure mechanical connection without welding, using processes like stamping to engage locking portions with retaining holes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If welding is used to connect the mounting bracket to the thermal module, then the connection strength is improved, but the manufacturing cost increases and environmental hazards occur

Engineering Contradiction:

Improveconnection strengthVSAvoidmanufacturing cost

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The connection mechanism is segmented into modular components: the mounting bracket with retaining holes and the thermal module with locking portions. This segmentation allows for non-welded mechanical connection through engagement of these discrete parts, eliminating welding costs while maintaining connection strength.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The welding process (thermal/chemical joining) is replaced with a mechanical connection system consisting of locking portions engaging with retaining holes. This substitution eliminates the need for welding equipment, reduces manufacturing costs, and removes environmental hazards associated with welding while providing sufficient connection strength.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If welding is used to connect the mounting bracket to the thermal module, then the connection strength is improved, but misalignment may occur

Engineering Contradiction:

Improveconnection strengthVSAvoidlocation accuracy

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

The locking portions are pre-formed on the thermal module at precise locations before assembly. These pre-positioned locking portions guide the mounting bracket into correct alignment as they engage with the retaining holes, ensuring accurate location before the connection is finalized, thereby preventing misalignment issues.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The locking portions act as intermediary elements that mediate the connection between the mounting bracket and thermal module. These intermediaries provide precise geometric engagement features that ensure correct alignment and positioning, eliminating misalignment problems associated with direct welding.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If welding is used to connect the mounting bracket to the thermal module, then the connection is secured, but environmental hazards and process hazards occur

Engineering Contradiction:

Improveconnection reliabilityVSAvoidenvironmental hazards

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The welding process (which generates environmental hazards such as fumes, sparks, and heat) is replaced with a cold mechanical connection system using locking portions and retaining holes. This substitution maintains connection reliability through secure mechanical engagement while completely eliminating the environmental and process hazards associated with welding operations.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Ease of manufacture

If locking portions are used to connect the mounting bracket to the thermal module, then the manufacturing cost is reduced, but the connection strength may be insufficient

Engineering Contradiction:

Improvemanufacturing costVSAvoidconnection strength

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

Multiple locking portions are provided on the thermal module, and multiple retaining holes are provided on the mounting bracket. The combined effect of multiple engagement points distributes the connection load and provides cumulative locking strength, ensuring that the overall connection strength is sufficient to secure the mounting bracket firmly to the thermal module while maintaining cost-effectiveness.

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS9625218B2Method of manufacturing a heat dissipation device

Publication Date: 2017.04.18 ASIA VITAL COMPONENTS CO LTD

AI summary

A heat dissipation device includes a mounting bracket and a thermal module. The mounting bracket has at least one retaining hole and a mounting section, and the thermal module includes a plurality of radiating fins, to which the mounting bracket is connected. On the radiating fins, at least one engaging zone is provided for correspondingly engaging with the mounting bracket, and at least one locking portion is formed for correspondingly engaging with the retaining hole. With the above structural design, the mounting bracket can be more firmly and stably connected to the thermal module and be more accurately located on the radiating fins without the need of welding, so that the manufacturing cost for welding is saved. A method of manufacturing the heat dissipation device is also disclosed.