Segmented Heat Sink Assembly for Low-Cost Thermal Dissipation
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Solution Overview
Problem
Existing heat sinks face challenges in manufacturing complexity, high production costs, and limited thermal conductivity due to complex structures and materials, especially with larger sizes and more specific designs, making them difficult to produce efficiently and at a low cost.
Innovation Solution
A heat sink design comprising a bottom frame with a recessed cavity and step groove, combined with a heat dissipation element featuring a heat-conducting plate and protrusions, allowing separate manufacturing and assembly through die-casting for the frame and extrusion or machining for the element, with hermetic connections using methods like stir friction welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If die-casting integrated molding is used to manufacture heat sinks with larger size and more complex structure, then the heat dissipation efficiency can be improved, but the manufacturing cost increases significantly and the qualification rate decreases
Solution Approach 1:
The heat sink is divided into two separate components: the bottom frame manufactured by die-casting and the heat dissipation element manufactured by extrusion or machining. This segmentation allows each component to be optimized for its specific manufacturing process, avoiding the high costs and low qualification rates of complex integrated die-casting while maintaining effective heat dissipation through controlled thermal coupling via the heat-conducting protrusion and through slot.
2Temperature
If heat dissipation teeth are made higher to improve heat dissipation efficiency, then the contact area with air increases, but the difficulty of demolding increases and tooth height is limited
Solution Approach 1:
The heat dissipation element is separated from the bottom frame, allowing the heat dissipation teeth to be manufactured as a standalone extruded or machined component. This eliminates the demolding constraints of integrated die-casting, enabling the creation of taller, more efficient heat dissipation teeth without increasing manufacturing difficulty.
Solution Approach 2:
The manufacturing method of the heat dissipation element is changed from die-casting to extrusion or machining. These alternative processes have no demolding limitations, allowing the heat dissipation teeth to be made significantly taller and more complex while improving heat dissipation efficiency without increasing demolding difficulty.
3Ease of manufacture
If aluminum extrusion is used to manufacture heat sinks, then the manufacturing process is simple, but the desired specific structure cannot be obtained
Solution Approach 1:
The heat sink is segmented into the bottom frame (die-casted with high structural specificity) and the heat dissipation element (extruded or machined with manufacturing simplicity). This allows each component to achieve its optimal manufacturing characteristics while the assembled whole achieves both structural specificity and manufacturing efficiency.
Solution Approach 2:
Two different manufacturing approaches (die-casting for the bottom frame and extrusion/machining for the heat dissipation element) are merged into a single heat sink assembly. The bottom frame provides the structurally specific housing and mounting features, while the heat dissipation element provides the thermally optimized fin structure, combining the advantages of both manufacturing methods.
4Manufacturing precision
If machining is used to carve the required shape for heat sinks, then the desired shape can be achieved, but the processing efficiency is low and mass production cost is too high
Solution Approach 1:
The heat dissipation element is segmented as a separate extruded or machined component that can be mass-produced with high efficiency. The bottom frame is die-casted with the required structural features. This segmentation allows the majority of the component (heat dissipation element) to be manufactured using high-volume extrusion processes rather than expensive and slow machining operations.
Solution Approach 2:
The manufacturing method for the heat dissipation element is changed from machining to extrusion or machining of simpler forms. Extrusion is a high-speed, high-volume process ideal for mass production, and when combined with the die-casted bottom frame, achieves both shape accuracy and high productivity at low mass production cost.
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
Facilitates easy mass production with high thermal conductivity and improved structural integrity, ensuring efficient heat dissipation performance while reducing manufacturing difficulties and costs.
Implementation Method 1
The outer wall of the heat-conducting protrusion is hermetically connected to the inner wall of the through slot
Implementation Method 2
They are generally composed of a series of vertically or horizontally arranged heat dissipation teeth, which can increase the contact area with the surrounding air, thereby accelerating the heat transfer rate from the heat source to the air
Implementation Method 3
the outer wall of the heat-conducting protrusion and the inner wall of the through slot are welded by stir friction welding
Data Source
AI summary
A heat sink includes a bottom frame and heat dissipation element; a side of the bottom frame is provided with a recessed cavity for receiving a heat element, the other side of the bottom frame away from the recessed cavity is provided with a step groove, an inner bottom wall thereof is provided with a through slot in communication with the recessed cavity; the heat dissipation element includes a heat-conducting plate, a heat-conducting protrusion, and several heat dissipation teeth; each heat dissipation tooth is spaced apart on the same side of the heat-conducting plate, the heat-conducting protrusion is arranged on the side of the heat-conducting plate away from the heat dissipation teeth; the heat-conducting plate is accommodated in the step groove, and the heat-conducting protrusion is passed through the through slot; the outer wall of the heat-conducting protrusion is hermetically connected to the inner wall of the through slot.