Heat Sink Base With Notched Protrusions For Heat Pipe Bonding
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Solution Overview
Problem
Conventional heat sink designs face issues with insufficient bonding strength and reduced thermal conduction due to inadequate fixation of heat pipes, often requiring soldering which can lead to poor contact and low yield rates, and uniformity challenges with protruding ribs in aluminum extrusion-based bases.
Innovation Solution
A heat sink design featuring a base with parallel concave heated areas and protrusions with notches, allowing heat pipes to be embedded lengthwise, where the notches compress to form a deformation portion for enhanced contact and bonding, eliminating the need for soldering and improving thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If heat pipes are embedded directly into the base of the heat sink, then the thermal conduction effect is improved, but the bonding strength is insufficient
Solution Approach 1:
The protrusions are pre-formed on the base before heat pipe installation, creating predetermined bonding structures that will engage with the heat pipes during compression. This preliminary preparation ensures both thermal contact and mechanical bonding strength are achieved simultaneously when the heat pipes are pressed into place.
Solution Approach 2:
The base is designed with localized protrusions at specific positions where heat pipes need to be secured. These protrusions concentrate the bonding function at precise locations rather than requiring uniform bonding across the entire base, enabling strong mechanical attachment while maintaining optimal thermal conduction paths.
2Strength
If additional structures are added between the heat pipes to embed them securely, then the bonding strength is improved, but the thermal conduction effect is reduced significantly
Solution Approach 1:
The bonding structure and thermal conduction path are merged into a single integrated design. The protrusions serve dual functions: providing mechanical bonding strength while simultaneously maintaining direct thermal contact between the heat pipes and base, eliminating the need for separate bonding structures that would interfere with heat transfer.
Solution Approach 2:
The protrusions are designed to perform multiple functions simultaneously: they provide mechanical support, enable secure bonding through compression, ensure proper positioning of heat pipes, and maintain optimal thermal conduction. This multi-functionality eliminates the need for additional specialized structures.
3Ease of manufacture
If the grooves are arranged adjacent to one another to install heat pipes, then the heat pipe installation is simplified, but the function of fixing the heat pipes is lost significantly
Solution Approach 1:
The base is segmented into multiple heating areas with protrusions positioned between them, creating distinct zones for heat pipe installation. This segmentation provides both organized placement (ease of manufacture) and mechanical fixation points (fixing function) through the protrusions that extend into the spaces between heating areas.
4Strength
If solder is used to solder the heat pipes into the grooves, then the heat pipe fixation is improved, but the manufacturing process becomes complicated and the yield rate decreases
Solution Approach 1:
The mechanical compression system replaces the soldering process entirely. By applying compression force through the pressing device, the heat pipes are mechanically secured to the base through the protrusions without requiring thermal bonding processes like soldering, thereby simplifying the manufacturing process and improving yield rate.
Solution Approach 2:
The compression process causes the heat pipes to deform and conform to the protrusions automatically, creating a self-fixing mechanism. The heat pipes themselves provide the bonding interface through their deformation, eliminating the need for external soldering materials or complex bonding procedures.
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 design achieves strong bonding and efficient thermal conduction by ensuring direct contact between heat pipes and the base, increasing the contact surface area and reducing manufacturing complexity while preventing heat pipe damage.
Implementation Method 1
a component such as a heat pipe is added to the bottom of a heat sink to improve the thermal conduction effect
Implementation Method 2
The notch of each heat pipe may be compressed and deformed, so as to provide good contact, thermal conduction, and bonding strength
Implementation Method 3
a plurality of fins extending from the second surface of the base
Implementation Method 4
a plurality of fins extending from the second surface of the base
Data Source
AI summary
A heat sink and its manufacturing method. The heat sink includes a base and plural heat pipes. The base has a first surface, plural parallel heated areas concavely formed on the first surface, a protrusion disposed between any two heated areas and protruding in a direction towards the first surface, and at least one notch formed on each protrusion. A first protrusion portion and a second protrusion portion are formed at the top of the protrusion and the top of notch respectively. The heat pipes are embedded into the heated areas respectively in the lengthwise direction, and the heat pipes at the notches of the protrusions are attached and in contact with each other. The notch of each heat pipe may be compressed and deformed, so that the heat pipes are in contact with each other.