Injection-Free Vapor Chamber Manufacturing via High-Energy Welding
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Solution Overview
Problem
Conventional heat-dissipating devices, such as vapor chambers, often have inefficiencies in temperature uniformity and are prone to damage due to exposed injection tubes, which are unreliable and susceptible to stress and damage during the manufacturing process.
Innovation Solution
A method of manufacturing a heat-dissipating device without an injection tube, involving an upper and lower casing with a receiving space containing a capillary and a brace, where the capillary and brace are sintered to the casings and sealed hermetically, using high-energy welding, creating a smooth, sealed surface for liquid medium injection and phase change to enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an injection tube is used to fill the liquid working medium, then the device can be manufactured, but the exposed injection tube becomes a stress concentration point that is susceptible to damage and reduces reliability
Solution Approach 1:
The invention extracts and eliminates the injection tube from the final device structure. Instead of leaving an exposed injection tube that protrudes from the vapor chamber, the method seals the injection location within the device body through high-energy welding, completely removing the problematic external injection tube structure that causes stress concentration.
Solution Approach 2:
The invention changes the physical state and properties of the injection location by applying high-energy welding to seal the crevice. This transforms the open injection tube structure into a sealed internal structure, changing the parameter of the injection location from exposed to sealed, thereby eliminating stress concentration points.
2Temperature
If conventional manufacturing processes are used with injection tubes, then the device can be assembled, but temperature uniformity and heat transfer efficiency are poor
Solution Approach 1:
The invention replaces conventional mechanical welding and sealing methods with high-energy welding technology. This substitution enables precise control over the sealing process, creates more uniform internal structures, and improves temperature distribution while maintaining manufacturing feasibility.
Solution Approach 2:
The invention employs composite construction by sintering the capillary and brace to the upper and lower casings, creating a composite structure that integrates multiple materials with complementary properties. This composite approach improves both temperature uniformity and manufacturing control.
3Ease of manufacture
If the injection tube is exposed outside the vapor chamber, then the liquid working medium can be filled, but the exposed tube is likely to be hit and severed
Solution Approach 1:
The invention merges the injection function with the sealed casing structure. Instead of having a separate exposed injection tube, the injection location is integrated into and sealed by the upper and lower casings through high-energy welding, combining the filling function with the structural housing.
Solution Approach 2:
The invention performs preliminary sealing of the injection location during the manufacturing process before the device is put into service. The high-energy welding seals the crevice permanently during assembly, preventing future damage that would occur if an exposed tube remained.
4Reliability
If welding and sealing steps are added to eliminate the injection tube, then reliability improves, but manufacturing complexity increases
Solution Approach 1:
The invention replaces multiple separate manufacturing steps (drilling, pipe-welding, vacuum filling, sealing, spot welding) with a integrated high-energy welding process. This substitution reduces the number of discrete steps while achieving the same or better sealing and structural integrity, thereby improving reliability without proportionally increasing complexity.
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 results in a reliable, high-performance heat-dissipating device with improved temperature uniformity and reduced risk of damage, eliminating the need for exposed injection tubes and enhancing heat transfer efficiency.
Implementation Method 1
the capillary and the brace are sintered to thereby be coupled to the upper casing and the lower casing
Implementation Method 2
a crevice formed by welding a seam between the upper and lower casings and sealed hermetically by high-energy welding
Implementation Method 3
Conventional heat-dissipating devices, such as flat heat pipes, loop heat pipes, and vapor chambers, perform heat transfer by a liquid phase change of a working medium
Implementation Method 4
CN1832156 discloses a radiating device... said capillary structure includes multiple grooves formed on the inside wall of the cavity and porous powder sintered under high temperature on the inside wall , thus the radiating device has good capillary force of sintered capillary structure
Data Source
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AI summary
A method of manufacturing a heat-dissipating device without injection tube and an object manufactured by the method. The method includes the steps of: a) providing an upper casing and a lower casing, wherein a receiving space is defined between the upper casing and the lower casing; b) positioning a capillary and a brace in the receiving space, welding the upper casing and the lower casing in a manner to seal a seam therebetween hermetically, and reserving a crevice; c) sintering; d) injecting a liquid working medium from the crevice into the receiving space; and e) putting the combination of the upper casing and the lower casing into which the liquid working medium has been injected in step d) in a vacuum environment and welding the crevice quickly to seal the crevice hermetically. An exposed heat-dissipating device without injection tube effective in dissipating heat is manufactured by the method.