Powder-Formed Cooling Elements for Thin Heat Sink Structures
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing cooling technologies for power electronics components, such as power semiconductors, generate significant waste and are inefficient in producing thin, high-performance cooling elements due to machining limitations and material stiffness.
Innovation Solution
A method using metallic powder to create a green compact via metal powder injection molding or additive processes, sintering to form a preform, and forming cooling structures through press forming or sinter forging, allowing for waste-free production of complex shapes and increased productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If machining is used to produce cooling elements, then manufacturing precision can be achieved, but material waste is generated and production time increases
Solution Approach 1:
The invention changes the material state from solid to powder form, enabling direct forming of cooling elements without machining. The metallic powder is compacted and sintered to create the final product, eliminating material removal and waste generation while maintaining manufacturing precision through controlled densification processes
Solution Approach 2:
The invention replaces the mechanical machining system with a powder metallurgy forming system. Instead of removing material through cutting tools, the cooling elements are formed by compacting and sintering metallic powder directly into the desired shape, achieving both precision and waste reduction
2Strength
If solid material is used for cooling elements, then structural strength is maintained, but forming complexity and production time increase
Solution Approach 1:
The invention changes the material state from solid to powder, which fundamentally alters the forming characteristics. The powder can be easily compacted and sintered into complex geometries without the time-consuming machining operations required for solid materials, thereby increasing productivity while maintaining strength through controlled densification
Solution Approach 2:
The invention utilizes the porous nature of sintered powder materials during the forming process. The powder compact allows for easy formation of complex shapes, and the subsequent sintering process creates a porous structure that can be optimized for both strength and thermal performance, enabling faster production of complex cooling elements
3Ease of manufacture
If conventional cooling elements are produced, then manufacturing simplicity is maintained, but thermal performance and heat exchange efficiency are limited
Solution Approach 1:
The invention changes the material from solid to powder form, enabling the creation of complex internal structures and optimized geometries that significantly improve heat exchange efficiency. The powder metallurgy process allows for intricate channel networks and surface structures that enhance thermal performance while maintaining manufacturing simplicity through a single integrated forming process
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 method enables the production of high-performance cooling devices with thin elements that enhance heat exchange, reduce thermal resistance, and improve flexibility in design, while minimizing material waste and production time.
Implementation Method 1
a green compact being produced from the powder either by means of metal powder injection molding or by means of an additive process, which green compact is sintered to form a preform
Implementation Method 2
the cooling structure in the form of cooling elements is produced from the preform by press forming, for which purpose a part of the preform is pressed through or into a mold, or wherein a green compact is produced from the powder by pressing
Implementation Method 3
these components generate large amounts of heat during operation, which often needs to be dissipated using a cooling medium
Data Source
AI summary
A method for producing a cooling device includes the steps of providing a material and configuring a cooling structure from the material, wherein a metallic powder is used as the material, a green compact being produced from the powder either by metal powder injection molding or by an additive process, which green compact is sintered to form a preform, and the cooling structure in the form of cooling elements is produced from the preform by press forming, for which purpose a part of the preform is pressed through or into a mold, or wherein a green compact is produced from the powder by pressing, wherein the green compact is sintered to form the preform and wherein the cooling structure with the cooling elements is produced by sinter forging.