Liquid Cooling Head Assembly for Faster Welding and Corrosion Control
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Solution Overview
Problem
Current liquid cooling head manufacturing methods are inefficient, leading to prolonged manufacturing times and increased costs, while also failing to effectively address galvanic corrosion between heterogeneous materials.
Innovation Solution
The method involves heterogeneous material welding using a liquid cooling head design that includes a liquid channel main body, heat dissipation bottom plate, heat sink, and cover plate, where nickel layers are applied to prevent corrosion and improve weldability, with friction stir welding and soldering pastes used to secure components, and water baffles to guide the working fluid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional manufacturing methods are used for liquid cooling head, then manufacturing process is simple, but manufacturing time is prolonged and cost increases
Solution Approach 1:
The liquid cooling head is divided into multiple components including liquid channel main body, heat dissipation bottom plate, heat sink, and cover plate that can be manufactured separately and then assembled through welding, enabling parallel manufacturing and reducing overall production time
Solution Approach 2:
The patent employs heterogeneous materials (aluminum and copper) for different components to optimize thermal conductivity and manufacturing efficiency, with aluminum used for liquid channel main body and cover plate, and copper for heat dissipation bottom plate and heat sink
2Reliability
If heterogeneous materials are used for different components, then heat dissipation efficiency is improved, but galvanic corrosion occurs between materials
Solution Approach 1:
A nickel layer is applied as an intermediary coating on the aluminum surfaces (liquid channel main body and cover plate) that contact copper components, preventing direct galvanic interaction between dissimilar metals while maintaining thermal conductivity
Solution Approach 2:
The surface properties of aluminum components are modified by adding nickel plating, changing the material composition and electrochemical properties to prevent corrosion while preserving the desired thermal performance
3Reliability
If nickel layers are applied to prevent corrosion, then weldability is improved, but manufacturing steps increase
Solution Approach 1:
The nickel layers are applied to the aluminum components before the welding process, preparing the surfaces in advance to ensure proper weldability and prevent corrosion during and after assembly
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 reduces manufacturing time and cost, enhances product accuracy and reliability, and prevents galvanic corrosion, thereby improving the heat dissipation efficiency and weld quality of the liquid cooling head.
Implementation Method 1
the cover plate is sealed to the liquid channel main body with a friction stir welding to form a weld run between the cover plate and the liquid channel main body
Implementation Method 2
the heat dissipation bottom plate and the heat sink are fixed in the different recessed indentations of the liquid channel main body with soldering pastes
Data Source
AI summary
A liquid cooling head manufacturing method includes the following steps. First, a liquid channel main body is provided. Then, a heat dissipation bottom plate and a heat sink are disposed in different recessed indentations in the liquid channel main body. The heat dissipation bottom plate and the heat sink are welded in the liquid channel main body and a cover plate is sealed on the liquid channel main body.