Additive Manufacturing Thermal Diffuser with 3D Lattice
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Solution Overview
Problem
The manufacturing of diphasic thermal diffusers, such as steam chambers, is complex and costly due to the need for precise assembly of capillary structures and mechanical support elements, which are subject to mechanical and thermal stresses.
Innovation Solution
A diphasic thermal diffuser with a three-dimensional trellis structure made of parallelepiped or hexahedral meshes, which provides capillary action for heat transfer fluid movement and mechanical support, fabricated using additive manufacturing techniques like laser fusion on a powder bed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembly methods are used to manufacture two-phase thermal diffusers with capillary structures, then the mechanical support and capillary functions can be achieved, but the manufacturing process becomes complex and costly
Solution Approach 1:
The patent combines the mechanical support structure and the capillary structure into a single integrated three-dimensional lattice structure manufactured by additive manufacturing. This merging eliminates the need for separate assembly of mechanical supports and capillary elements, thereby reducing manufacturing complexity while maintaining both mechanical support and capillary functions.
Solution Approach 2:
The three-dimensional lattice structure serves multiple functions simultaneously: it provides mechanical support to the envelope, enables capillary action for heat transfer fluid movement, and facilitates heat diffusion. This multi-functionality reduces the number of separate components needed, simplifying the manufacturing process.
2Reliability
If separate manufacturing and assembly of capillary structures and mechanical supports are performed, then functional performance is achieved, but manufacturing cost increases
Solution Approach 1:
The patent merges the manufacturing of mechanical supports and capillary structures into a single additive manufacturing process. This consolidation eliminates multiple manufacturing steps, reduces assembly operations, and lowers overall manufacturing cost while maintaining the required heat transfer performance.
Solution Approach 2:
The patent utilizes additive manufacturing parameters (such as lattice geometry, cell size, and material distribution) to optimize both mechanical properties and capillary performance simultaneously. By adjusting these parameters during the manufacturing process, the invention achieves functional performance requirements at lower cost compared to traditional multi-step manufacturing.
3Manufacturing precision
If complex assembly processes are used for manufacturing thermal diffusers, then precise positioning of components is achieved, but manufacturing time increases
Solution Approach 1:
The patent combines all structural elements into a single monolithic component manufactured by additive manufacturing. This eliminates the need for precise assembly and positioning of separate components, thereby maintaining manufacturing precision while dramatically increasing production speed.
Solution Approach 2:
The additive manufacturing process creates the final three-dimensional lattice structure with precise geometry and positioning in a single continuous manufacturing operation. The precise positioning of lattice elements is achieved during the manufacturing process itself, eliminating the need for subsequent assembly and positioning operations.
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 trellis structure simplifies manufacturing by allowing layer-by-layer construction without suspended elements, enhances capillary effect for efficient heat transfer, and provides mechanical support to resist pressure variations, resulting in a more efficient and cost-effective thermal diffuser.
Implementation Method 1
Returning the fluid to the liquid state at the hot spot is an important step and can be achieved by active methods using a pump, or by passive methods using capillary systems
Implementation Method 2
The fluid under the effect of the heat evaporates locally while remaining in the internal volume (or cavity) of the sealed envelope and moves to cooler areas far from the localized source, where it condenses
Implementation Method 3
moves to cooler areas far from the localized source, where it condenses before being brought back or returning by itself to the heat zone
Implementation Method 4
This manufacturing process involves fusing the powder composed of the desired material for manufacturing, in this case stainless steel. The laser forms the desired structure layer by layer
Data Source
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Figure 5
AI summary
The invention relates to a two-phase thermal diffuser (10), said diffuser comprising a casing (11), an internal volume (20) for receiving a heat transfer fluid, and an internal structure for the condensation and capillary movement of said fluid. The internal structure comprises a three-dimensional lattice (9) extending through all or part of the internal volume (20) and supported by opposite portions of the casing (11), said lattice (9) being composed of body-centered hexahedral meshes (1).