Sintered Cooling Elements With Multi-Stage Forming for Higher Surface Area
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Solution Overview
Problem
Cooling devices for power electronics face limitations in cooling performance due to mechanical strength constraints, which restrict the size and number of structural elements that can be used, thereby limiting the surface area for heat dissipation.
Innovation Solution
A method involving the use of sintered powder to create a cooling structure through multi-stage forming, where a green compact is pressed and sintered to form cooling elements with increased surface area without waste material, allowing for higher cooling elements with improved mechanical strength and reduced risk of damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the size of structural elements is reduced to increase surface area for cooling, then cooling performance is improved, but mechanical strength deteriorates
Solution Approach 1:
The patent applies parameter changes by transitioning from solid material to sintered material, which fundamentally alters the material properties. The sintered material enables the production of cooling elements with high surface area while maintaining adequate mechanical strength through controlled porosity and sintering parameters, thus resolving the contradiction between surface area and strength
Solution Approach 2:
The patent uses composite materials by combining sintered powder with binding agents to create a composite structure that maintains mechanical integrity while providing the required surface area for cooling. The composite nature allows optimization of both strength and surface area properties
2Manufacturing precision
If traditional machining methods are used to produce cooling elements, then manufacturing precision is achieved, but material waste increases and productivity decreases
Solution Approach 1:
The patent employs porous sintered materials that can be directly formed into complex cooling element geometries without traditional machining. This porous forming approach enables near-net-shape production, significantly reducing material waste and improving productivity while maintaining sufficient manufacturing precision for cooling applications
Solution Approach 2:
The patent replaces traditional mechanical machining processes with a sintering and forming process. Instead of removing material through cutting or grinding, the cooling elements are directly formed from sintered powder, eliminating the need for subsequent machining operations and thereby improving productivity and reducing waste
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 enhances cooling performance by increasing the surface area of cooling elements while maintaining mechanical integrity, allowing for more efficient heat dissipation without the need for additional machining, thus improving productivity and corrosion resistance.
Implementation Method 1
a green compact is produced by pressing
Implementation Method 2
the green compact is sintered to form a preform
Data Source
AI summary
A method for producing a cooling device includes the steps of providing a material and forming a cooling structure from the material, a sinter powder being used as the material, from which a green compact is produced by pressing, the green compact being sintered into a preform, and the cooling structure in the form of cooling elements being produced from the preform by forming, for which a part of the preform is pressed through a forming tool, forming being carried out in a plurality of forming steps.