Nonlinear Fin Liquid Cooling Structure for Leak-Proof Heat Dissipation
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Solution Overview
Problem
Existing liquid-cooling radiators fail to meet the heat dissipation requirements of high-performance automotive electronics due to insufficient efficiency, stability, and reliability.
Innovation Solution
A liquid-cooling heat dissipation structure with a nonlinear fin array, comprising an upper and lower plate with brazing areas and a flow guide member, where the flow guide member is connected to the plates to form an enclosed cavity for heat dissipation columns, enhancing leak-proof ability and reliability through brazing and friction stir welding processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional liquid-cooling radiators are used, then the structure is simple and easy to manufacture, but the heat dissipation efficiency is insufficient for high-performance automotive electronics
Solution Approach 1:
The radiator is divided into multiple heat dissipation regions with different fin densities. The fin array is segmented into first, second, and third regions with progressively higher fin densities, allowing each segment to optimize heat dissipation for its specific thermal load while maintaining overall system efficiency.
Solution Approach 2:
Different regions of the radiator are assigned different fin densities based on local heat generation characteristics. The first region has lower fin density for areas with lower heat generation, while the second and third regions have progressively higher fin densities for areas with higher heat generation, optimizing heat dissipation efficiency locally.
2Reliability
If conventional joining methods are used, then the manufacturing process is simple, but the leak-proof ability and reliability are insufficient
Solution Approach 1:
Multiple joining methods (brazing, friction stir welding, and adhesive bonding) are combined to create a multi-layered joining system. The brazing process provides primary structural integrity and leak-proofing, friction stir welding reinforces the joints, and adhesive bonding provides additional sealing, collectively enhancing reliability beyond what any single method could achieve.
Solution Approach 2:
The joining system uses composite material approaches by combining different joining technologies. The aluminum alloy plates are joined through a composite process involving brazing alloys, friction stir welding material transfer, and adhesive materials, creating a multi-modal joint that leverages the strengths of each method for superior leak-proof ability and reliability.
3Productivity
If uniform fin density is used throughout the radiator, then the manufacturing process is simple, but the heat dissipation efficiency cannot meet the varying thermal requirements of different components
Solution Approach 1:
The fin array transitions from a static uniform structure to a dynamic gradient structure where fin density varies continuously or in steps across different regions. This dynamic adaptation of fin density to local thermal requirements allows the radiator to efficiently dissipate heat from components with varying power densities without requiring multiple separate radiators.
Solution Approach 2:
The fin density parameter is changed across different regions of the radiator. The first region has a first fin density, the second region has a second fin density higher than the first, and the third region has a third fin density higher than the second. This parameter variation optimizes heat dissipation efficiency for components with different thermal characteristics.
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
The structure achieves improved heat dissipation efficiency, stability, and reliability by strengthening the joint strength and leak-proof ability, ensuring effective thermal conductivity and reduced moisture travel paths.
Implementation Method 1
an upper brazing area arranged around the accommodating groove... a lower brazing area arranged around the lower joint area... The upper brazing area of the upper plate is connected to the lower brazing area of the lower plate
Implementation Method 2
The first surface of the flow guide member is flush with a bottom surface of the lower plate, and the first surface of the heat dissipation plate body is exposed from the lower plate for being in contact with a plurality of traction inverter power component sets
Data Source
AI summary
A liquid-cooling heat dissipation structure having a nonlinear fin array. The liquid-cooling heat dissipation structure includes an upper plate, a lower plate, and a flow guide member. The upper plate has an accommodating groove of which an inner side has an upper joint area formed thereon. The lower plate has a lower joint area. The flow guide member disposed between the upper plate and the lower plate includes a heat dissipation plate body having a first surface and a second surface, and a plurality of heat dissipation columns integrally disposed on the second surface. The upper brazing area is connected to the lower brazing area, and two ends of the flow guide member are respectively connected to the upper joint area and the lower joint area to form an enclosed cavity for accommodating the heat dissipation columns.