Caulked Heat Pipe Structure With Gap-Filling Metal Interface
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Solution Overview
Problem
Existing heat pipe structures connected to base blocks using caulking methods suffer from air gaps, which reduce heat transferability and fixing stability, especially at bent parts, and require complex soldering processes.
Innovation Solution
A heat pipe structure with a recessed part and projecting wall parts, using metals or metal alloys with specific melting points to fill air gaps and ensure stable fixation, combined with a manufacturing method that forms metal parts between the heat pipe and base block.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If caulking method is used to connect heat pipe to base block, then operation complexity is reduced and cost is lowered, but air gaps form between base block and heat pipe reducing heat transferability
Solution Approach 1:
A solder layer is introduced as an intermediary substance between the heat pipe and base block. The solder fills air gaps that form during caulking connection, creating a thermal bridge that improves heat transferability while allowing the simpler caulking method to be used for fixation.
Solution Approach 2:
The connection structure becomes composite by combining mechanical caulking fixation with thermal solder bonding. This composite approach leverages the advantages of both methods: caulking provides easy operation and fixation stability, while solder provides excellent heat transferability by eliminating air gaps.
2Reliability
If soldering method is used to connect heat pipe to base block, then heat transferability is improved, but operation becomes complicated and cost increases
Solution Approach 1:
Instead of using complete soldering for both fixation and thermal connection, the patent applies soldering partially - only for filling air gaps in the thermal connection path. The primary fixation is achieved through simpler caulking, reducing overall operation complexity while maintaining heat transferability.
Solution Approach 2:
The patent merges caulking and soldering methods into a hybrid connection process. Caulking provides mechanical fixation and positioning, while solder is applied subsequently to fill gaps and ensure thermal contact, combining the benefits of both methods while minimizing their individual drawbacks.
3Adaptability or versatility
If heat pipe has bent parts to adapt to base block, then adaptability is improved, but caulking operation becomes more difficult and heat pipe may be damaged by heat generation temperatures
Solution Approach 1:
The solder layer is applied in advance or during the caulking process to protect bent parts of the heat pipe before they undergo caulking deformation. This preliminary thermal bonding prevents damage during the caulking operation while maintaining the necessary bends for adaptability.
Solution Approach 2:
Solder acts as a protective intermediary layer on bent parts during caulking. This layer prevents direct mechanical damage to the heat pipe material during deformation while allowing the bent shape to be formed for adaptability to the base block surface.
4Reliability
If plating film is formed on base block before soldering, then connection reliability is improved, but manufacturing cost and process complexity increase
Solution Approach 1:
Instead of forming plating films on entire base blocks, the patent applies solder selectively only where needed - in air gaps between heat pipe and base block. This partial application reduces manufacturing complexity while maintaining connection reliability at critical interfaces.
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
Enhances heat transferability and fixing stability of the heat pipe to the base block, improving cooling efficiency while simplifying the connection process and preventing damage from heat generation.
Implementation Method 1
a first metal part containing first metal having a melting point equal to or higher than 130° C. and equal to or lower than 400° C. and/or a first metal alloy having a melting point equal to or higher than 130° C. and equal to or lower than 400° C. is formed between the recessed part and an outer surface of the container part
Implementation Method 2
The heat pipe transports heat received from the heat generating body, which is a cooling target, via the base block using latent heat due to a phase change of this working fluid
Implementation Method 3
The heat pipe transports heat received from the heat generating body, which is a cooling target, via the base block using latent heat due to a phase change of this working fluid
Data Source
AI summary
A base block has a longitudinal direction and a width direction and includes a recessed part in which a heat receiving tubular portion is accommodated, and a container part of a heat pipe is caulked and fixed in a recessed part and a first metal part containing first metal having a melting point equal to or higher than 130° C. and equal to or lower than 400° C. and/or a first metal alloy having a melting point equal to or higher than 130° C. and equal to or lower than 400° C. is formed between the recessed part and an outer surface of the container part.