Sintered Powder Cooling Device Forming Method
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Solution Overview
Problem
Existing cooling devices for high-precision components are complex and inefficient in production, often resulting in waste material and lower component precision, while also requiring machining for height adjustments and shape variations.
Innovation Solution
A method using sintered powder to produce a cooling device where a green compact is pressed and sintered into a preform, then formed into cooling elements with varying densities and shapes, allowing for calibration to achieve precise height adjustments and shapes without machining, using a perforated plate as a forming tool to simplify the process and reduce material waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional machining methods are used to produce cooling elements, then component precision can be achieved, but material waste is generated and production time increases
Solution Approach 1:
The patent changes the material state from solid to sintered powder, enabling near-net-shape forming that eliminates machining waste while maintaining precision through controlled sintering parameters and post-forming calibration
Solution Approach 2:
The patent performs preliminary forming of cooling elements with varying densities and shapes directly from the sintered preform, establishing the basic geometry before final calibration, thereby avoiding subsequent machining operations
2Manufacturing precision
If traditional machining methods are used for height adjustments, then precise dimensions can be achieved, but production time increases
Solution Approach 1:
The patent changes the material state to sintered powder, enabling direct forming of cooling elements with precise height control during the forming process, eliminating time-consuming machining operations while maintaining dimensional accuracy through calibration
Solution Approach 2:
The patent performs preliminary forming of cooling elements with target height dimensions directly from the sintered preform, establishing the basic geometry before final calibration to achieve precise height adjustments without machining
3Adaptability or versatility
If complex cooling element shapes are produced by machining, then design flexibility is achieved, but manufacturing complexity increases
Solution Approach 1:
The patent changes the material state to sintered powder, enabling direct forming of complex cooling element shapes with varying densities through controlled deformation during the forming process, simplifying manufacturing while achieving design flexibility
Solution Approach 2:
The patent performs preliminary forming of cooling elements with varying densities and complex shapes directly from the sintered preform using calibrated forming tools, establishing the final geometry in one operation without subsequent machining
4Ease of manufacture
If uniform density is maintained throughout the cooling structure, then production is simpler, but cooling performance is reduced
Solution Approach 1:
The patent applies local quality by creating varying density regions within the cooling structure - denser regions in areas requiring higher structural strength or heat dissipation, and less dense regions where weight reduction or material efficiency is prioritized, thereby optimizing both performance and manufacturing
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 enhances component precision, reduces production time, and increases productivity by eliminating waste material, enabling the production of complex cooling element shapes and height adjustments with improved corrosion resistance and flow behavior.
Implementation Method 1
a green compact is produced by pressing
Implementation Method 2
the green compact is sintered into 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, and the cooling structure is calibrated after forming.