Vapor Chamber Alignment Fixture for Laser Welding
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Solution Overview
Problem
Existing vapor chambers used for heat dissipation in electronic devices are challenging to manufacture due to rigidity and cost issues, and there is a need for improved alignment and welding methods for ultra-thin heat transfer devices.
Innovation Solution
A device and method for aligning parts prior to laser welding, utilizing a bottom welding fixture with fixed locating pins and alignment block assemblies, and a top welding fixture with wedge pusher assemblies to ensure precise alignment and efficient welding of vapor chamber components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If diffusion bonding is used to join copper layers, then the vapor chambers are durable and heat-resistant, but the manufacturing process is slow and expensive
Solution Approach 1:
The patent changes the joining method from diffusion bonding to laser welding, and modifies copper properties through cold working to increase rigidity. This allows use of thinner copper layers (0.002-0.005 inches) that can be welded more quickly while maintaining structural integrity and heat transfer performance.
Solution Approach 2:
The vapor chamber is divided into multiple copper layers (first copper layer, second copper layer, third copper layer) that are joined through laser welding. This segmentation allows for more efficient manufacturing compared to traditional diffusion bonding of solid copper blocks.
2Ease of manufacture
If copper layers are made thinner to reduce cost and improve flexibility, then manufacturing becomes more economical, but the parts become less rigid and harder to align
Solution Approach 1:
The patent applies cold working to the copper layers to increase their rigidity despite reduced thickness. The cold working process modifies the copper's mechanical properties, allowing thin layers (0.002-0.005 inches) to maintain sufficient structural integrity for alignment and welding operations.
Solution Approach 2:
Alignment blocks and locating pins are used to pre-position the thin copper layers before welding. This preliminary alignment ensures proper positioning despite the reduced rigidity of thinner copper, enabling accurate laser welding of the segmented structure.
3Manufacturing precision
If alignment blocks and locating pins are used to position parts, then welding precision is improved, but the device complexity increases
Solution Approach 1:
The alignment blocks and locating pins are integrated into the welding fixture itself, allowing the fixture to automatically position and align the copper layers during the welding process. This self-aligning mechanism reduces the need for additional external alignment devices and simplifies the overall setup.
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 solution enables the production of rigid, thin, and cost-effective vapor chambers with improved manufacturing efficiency, ensuring proper alignment and welding of ultra-thin heat transfer devices, addressing the limitations of existing technologies.
Implementation Method 1
two wedge pusher assemblies (40) functioning as actuators to align the vapor chamber parts with one another in horizontal and vertical directions
Implementation Method 2
alignment and welding of the parts that make up the ultra-thin heat transfer devices can be challenging
Data Source
AI summary
A device and method for alignment of parts for welding, having a bottom welding fixture and a top welding fixture. The bottom welding fixture has a plurality of fixed locating pins for positioning of parts to be welded and limiting movement of the parts in a first axis and a perpendicular second axis. At least pair of alignment block assemblies to actuate movement of the parts to be welded in the first and second axes. The alignment block assembly having an alignment block moveable from a first position to a second position for contacting and aligning the parts. An actuator coupled to the top welding or bottom welding fixture to actuate movement of the alignment block from the first position to the second position upon engagement of the top welding fixture to the bottom welding fixture.