Thin Vapor Chamber Support Structure Using Laser Weld Fixation

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Solution Overview

Problem

Conventional vapor chambers with thin designs face challenges in fixing support structures internally without altering the outer surface evenness, leading to recessed or protruding portions due to improper fixation methods like clamping between plates.

Innovation Solution

The use of laser welding to join support elements between two plates in a vapor chamber, ensuring secure fixation without increasing the product thickness, by applying laser welding on the outer surfaces of the plates corresponding to the support elements.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If support elements are fixed by clamping between two plates, then the support structure can be assembled, but the support elements tend to have displacement and the outer surface evenness is affected

Engineering Contradiction:

Improveassembly of support structureVSAvoidouter surface evenness

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical clamping system with a laser welding system. Instead of relying on mechanical pressure from plates to hold support elements in position, the invention uses laser welding to create permanent fixed connections between the support elements and the vapor chamber walls, eliminating displacement issues while maintaining manufacturing feasibility

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the fixation method from mechanical (clamping) to thermal (laser welding). By applying localized heat through laser welding, the support elements are permanently bonded to the vapor chamber structure, transforming the fixation mechanism from reversible mechanical pressure to irreversible thermal bonding, thereby ensuring positional stability

Inventive Principle:

Principle #35Parameter changes

2Reliability

If sintering is used to fix support elements, then the support structure is secured, but it is difficult to apply to thin vapor chambers

Engineering Contradiction:

Improvefixation of support elementsVSAvoidapplicability to thin vapor chambers

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The patent replaces the sintering process with laser welding. Sintering requires high temperature and pressure that are difficult to apply uniformly in thin structures. Laser welding provides localized, precise heating that can be effectively applied to thin vapor chambers, achieving reliable fixation without the limitations of sintering technology

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent transitions from a volumetric heating process (sintering) to a surface-level processing method (laser welding). The laser welding approach applies energy from one dimension (surface) rather than requiring volumetric heating, making it suitable for thin-walled structures where uniform volumetric heating would be difficult to achieve

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Productivity

If support elements are not properly fixed, then the vapor chamber can be manufactured, but recessed portions or protruding portions occur on the outer surface

Engineering Contradiction:

Improvemanufacturing of vapor chamberVSAvoidouter surface evenness

Core Design Contradiction:

ProductivityVSShape

Solution Approach 1:

The patent applies preliminary action by performing laser welding to fix support elements before the final assembly and sealing of the vapor chamber. This ensures that support elements are securely positioned and cannot cause surface irregularities during subsequent manufacturing steps or operation, preventing recessed or protruding portions from forming

Inventive Principle:

Principle #10Preliminary action

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 stabilizes the support structure within thin vapor chambers, maintaining outer surface evenness and enabling mass production by preventing displacement of support elements, thus enhancing product quality and production yields.

Implementation Method 1

On an outer surface of the first plate or the second plate, laser welding is applied on positions corresponding to the support elements so as to join the support elements to the first plate and the second plate and to form weld ports on the outer surface of any of the plates.

Methodology Applied

Scientific EffectLaser welding: Laser Beam Welding

Data Source

PatentUS11731220B2Vapor chamber with support structure and manufacturing method therefor

Publication Date: 2023.08.22 DELTA ELECTRONICS INC(CN)

AI summary

A vapor chamber with a support structure and its manufacturing method are provided. The vapor chamber with the support structure includes a first plate, a second plate spaced apart from the first plate, and multiple support elements fixed between the first and second plates. On an outer surface of any of the first plate or the second plate, laser welding is performed on positions corresponding to the support elements so as to join the support elements to the first and second plates and to form weld ports on the outer surface of any of the plates. The invention solves the problem of fixing the support structure inside the thin vapor chamber, and therefore mass production can be realized.