Laser-Patterned Vapor Chamber Wick for Faster Heat Spreader Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing capillary wick parts in vapor chambers, primarily through sintering, face limitations in productivity and design flexibility due to restrictive sintering conditions, leading to inefficiencies in heat dissipation performance.
Innovation Solution
A method utilizing a laser emitter to process a wick part on a base material, allowing for precise formation of engraved patterns with adjustable laser beam parameters such as mark speed and oscillation frequency, enabling quick and precise creation of capillary structures that enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a sintering method is used to manufacture capillary wick parts, then the wick part can be formed with porous structure, but the productivity is reduced due to restrictive sintering conditions
Solution Approach 1:
The patent replaces the traditional sintering method (thermal field) with a laser processing method (focused light field) to form capillary wick parts. The laser beam directly melts and fuses metal particles to create porous structures, eliminating the need for prolonged high-temperature sintering processes and thereby significantly improving productivity while maintaining manufacturing precision.
Solution Approach 2:
The patent changes the processing parameters from conventional sintering temperature and time to laser-specific parameters including laser power, scanning speed, and pulse duration. By optimizing these laser parameters, the method achieves rapid formation of capillary structures with controlled porosity, resolving the contradiction between precision and productivity.
2Manufacturing precision
If a sintering method is used to manufacture capillary wick parts, then the porous structure can be created, but the design flexibility is limited due to restrictive sintering conditions
Solution Approach 1:
The laser processing method replaces sintering, enabling direct digital control over the porous structure formation. The laser can be programmed to create various patterns, densities, and geometries of capillary channels by adjusting scanning paths and power parameters, thereby providing unlimited design flexibility while maintaining precise porous structure formation.
Solution Approach 2:
The patent introduces dynamic control of laser parameters during processing, allowing real-time adjustment of scanning speed, power, and pattern to create varied wick structures within a single component. This dynamic capability enables complex, non-uniform porous structures that cannot be achieved with static sintering processes.
3Productivity
If laser emitter is used to process wick part, then the productivity is improved by eliminating sintering restrictions, but the manufacturing complexity increases due to laser parameter control
Solution Approach 1:
The patent employs a universal laser processing system that can handle various materials, patterns, and geometries through software control. The same laser apparatus with programmable motion control can create different wick configurations by simply changing processing parameters, avoiding the need for multiple specialized tools and reducing overall manufacturing complexity despite the advanced technology involved.
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 eliminates sintering-related restrictions, improves heat dissipation performance by increasing the contact area with the refrigerant, and allows for varied design patterns, thereby enhancing the productivity and effectiveness of vapor chamber manufacturing.
Implementation Method 1
processing a wick part having a predetermined size into a predetermined engraved pattern by means of a predetermined emitted laser beam by using the laser emitter
Implementation Method 2
a capillary wick part, which is a porous body, is manufactured by a sintering method inside a body tube
Data Source
AI summary
Provided are a method for forming a wick part for a vapor chamber and a method for manufacturing the vapor chamber. The method for forming the wick part for the vapor chamber includes a base material preparation step for preparing a base material of a chamber body in which a refrigerant is accommodated, a laser installation step for setting a laser emitter on one side of the base material prepared in the base material preparation step, and a wick part processing step for processing a wick part having a predetermined size into a predetermined engraved pattern by means of a predetermined emitted laser beam by using the laser emitter installed in the laser installation step, thereby providing the advantage of being able to improve the product productivity of the vapor chamber.