Heat Pipe Riveting in Aluminum Plates for Gap-Free Thermal Contact
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Solution Overview
Problem
Existing heat dissipation systems for portable electronic devices face gaps and inefficiencies due to mechanical deformation of heat pipes and base plates, leading to reduced heat transfer efficiency, increased manufacturing complexity, and weight, while requiring additional heat-conducting media to compensate for gaps.
Innovation Solution
A tight-fit riveting process involving prefabricated heat pipes with cut-out portions and shaped aluminum plates forming caulking flanges to ensure precise fit and bonding without gaps, using rolling techniques to secure the heat pipe within the aluminum plate groove.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical riveting and flattening process is used to bond heat pipe to heat dissipation base plate, then the heat pipe can be secured in place, but gaps remain between the heat pipe and accommodating groove leading to insufficient tightness and reduced heat transfer efficiency
Solution Approach 1:
The patent applies preliminary action by pre-forming the heat pipe with a bent portion that matches the groove shape, and pre-coating the groove with heat-conducting paste before insertion. This preliminary preparation ensures that when the heat pipe is inserted, it automatically achieves tight contact with the groove walls without requiring additional deformation steps, thereby eliminating gaps and improving heat transfer efficiency.
Solution Approach 2:
The patent changes the geometric parameters of the heat pipe by pre-bending it to match the groove dimensions. The bent portion of the heat pipe is designed to correspond precisely to the groove shape, allowing the heat pipe to expand and fill the groove completely upon insertion. This parameter adjustment ensures tight fit and eliminates gaps that would otherwise reduce heat transfer efficiency.
2Reliability
If heat-conducting paste is applied to fill gaps between heat pipe and accommodating groove, then heat transfer effect is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent applies self-service by designing the heat pipe with a bent portion that automatically fills the groove and creates tight contact upon insertion. The geometry of the bent heat pipe is specifically designed to match the groove shape, allowing the component to self-align and self-seal the gap without requiring external intervention or additional materials like heat-conducting paste, thereby simplifying the manufacturing process.
3Manufacturing precision
If larger deformation is applied to heat pipe and heat dissipation base plate to improve fit, then tightness is improved, but the structure becomes heavier and requires thicker base plate
Solution Approach 1:
The patent applies preliminary action by pre-bending the heat pipe to match the groove shape before insertion. This preliminary deformation of the heat pipe eliminates the need for large-scale deformation of the base plate, allowing the use of thinner base plates and reducing the overall weight of the structure while still achieving tight connection.
4Shape
If two receiving grooves are formed on heat dissipation base plate to accommodate excess metal from riveting, then surface flatness is maintained, but fabrication complexity increases
Solution Approach 1:
The patent applies the taking out principle by removing the heat pipe from the deformation process. Instead of deforming the base plate and creating receiving grooves for excess metal, the heat pipe itself is pre-formed to match the groove shape. This extraction of the heat pipe as the active deformation element eliminates the need for complex receiving grooves and simplifies the base plate fabrication process while maintaining surface flatness.
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
Achieves improved heat transfer efficiency, reduced weight, and simplified manufacturing by ensuring a gap-free connection between the heat pipe and aluminum plate, allowing for thinner, lighter designs with enhanced precision and ease of fabrication.
Implementation Method 1
the heat pipe and the heat dissipation aluminum plate are bonded without gaps... improved heat transfer efficiency
Implementation Method 2
using rolling techniques to secure the heat pipe within the aluminum plate groove
Data Source
AI summary
A tight-fit riveting process for a heat dissipation aluminum plate and a heat pipe includes step 1, prefabricating a heat pipe: left and right sides of a flat surface of the heat pipe having cut-out portions; step 2, fabricating a heat dissipation aluminum plate: a thin aluminum plate being stamped in a top-down direction to form a groove and then extruded upward to form two caulking flanges; step 3, riveting and forming: the heat pipe being placed in the groove of the heat dissipation aluminum plate, the caulking flanges being deformed to caulk predetermined spaces between the cut-out portions and two sides of an opening of the groove, respectively.