EP4085738A1 - Additive manufactured heat sink - Google Patents
Additive manufactured heat sinkInfo
- Publication number
- EP4085738A1 EP4085738A1 EP21754223.2A EP21754223A EP4085738A1 EP 4085738 A1 EP4085738 A1 EP 4085738A1 EP 21754223 A EP21754223 A EP 21754223A EP 4085738 A1 EP4085738 A1 EP 4085738A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- baseplate
- heat sink
- chamber
- wick
- radiator
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
- 239000000654 additive Substances 0.000 title claims abstract description 21
- 230000000996 additive effect Effects 0.000 title claims abstract description 21
- 239000000463 material Substances 0.000 claims abstract description 55
- 239000003507 refrigerant Substances 0.000 claims abstract description 28
- 239000011148 porous material Substances 0.000 claims abstract description 20
- 238000004519 manufacturing process Methods 0.000 claims abstract description 19
- 239000007791 liquid phase Substances 0.000 claims abstract description 13
- 239000004020 conductor Substances 0.000 claims abstract description 7
- 239000012808 vapor phase Substances 0.000 claims abstract description 7
- 238000004891 communication Methods 0.000 claims abstract description 6
- 230000000704 physical effect Effects 0.000 claims description 25
- 238000000034 method Methods 0.000 claims description 23
- 239000007788 liquid Substances 0.000 claims description 14
- 239000011248 coating agent Substances 0.000 claims description 9
- 238000000576 coating method Methods 0.000 claims description 9
- 238000002844 melting Methods 0.000 claims description 9
- 230000008018 melting Effects 0.000 claims description 9
- 238000007789 sealing Methods 0.000 claims description 3
- 230000009969 flowable effect Effects 0.000 claims 1
- 230000009471 action Effects 0.000 abstract description 5
- 238000012546 transfer Methods 0.000 abstract description 5
- 239000008187 granular material Substances 0.000 description 5
- 239000000843 powder Substances 0.000 description 5
- 239000007787 solid Substances 0.000 description 5
- 239000012530 fluid Substances 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000002184 metal Substances 0.000 description 3
- 230000008569 process Effects 0.000 description 3
- 239000011800 void material Substances 0.000 description 3
- 241000931191 Scincidae Species 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 230000008901 benefit Effects 0.000 description 2
- 238000013461 design Methods 0.000 description 2
- 239000006260 foam Substances 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- 238000005266 casting Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 238000001704 evaporation Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D15/00—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies
- F28D15/02—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes
- F28D15/0233—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes the conduits having a particular shape, e.g. non-circular cross-section, annular
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
- B22F10/20—Direct sintering or melting
- B22F10/25—Direct deposition of metal particles, e.g. direct metal deposition [DMD] or laser engineered net shaping [LENS]
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/11—Making porous workpieces or articles
- B22F3/1103—Making porous workpieces or articles with particular physical characteristics
- B22F3/1109—Inhomogenous pore distribution
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F5/10—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
- B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
- B22F7/08—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
- B23P15/26—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass heat exchangers or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y10/00—Processes of additive manufacturing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B33—ADDITIVE MANUFACTURING TECHNOLOGY
- B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- B33Y80/00—Products made by additive manufacturing
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D15/00—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies
- F28D15/02—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes
- F28D15/04—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes with tubes having a capillary structure
- F28D15/046—Heat-exchange apparatus with the intermediate heat-transfer medium in closed tubes passing into or through the conduit walls ; Heat-exchange apparatus employing intermediate heat-transfer medium or bodies in which the medium condenses and evaporates, e.g. heat pipes with tubes having a capillary structure characterised by the material or the construction of the capillary structure
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/02—Manufacture or treatment of semiconductor devices or of parts thereof
- H01L21/04—Manufacture or treatment of semiconductor devices or of parts thereof the devices having at least one potential-jump barrier or surface barrier, e.g. PN junction, depletion layer or carrier concentration layer
- H01L21/48—Manufacture or treatment of parts, e.g. containers, prior to assembly of the devices, using processes not provided for in a single one of the subgroups H01L21/06 - H01L21/326
- H01L21/4814—Conductive parts
- H01L21/4871—Bases, plates or heatsinks
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/34—Arrangements for cooling, heating, ventilating or temperature compensation ; Temperature sensing arrangements
- H01L23/42—Fillings or auxiliary members in containers or encapsulations selected or arranged to facilitate heating or cooling
- H01L23/427—Cooling by change of state, e.g. use of heat pipes
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
- H05K7/00—Constructional details common to different types of electric apparatus
- H05K7/20—Modifications to facilitate cooling, ventilating, or heating
- H05K7/20009—Modifications to facilitate cooling, ventilating, or heating using a gaseous coolant in electronic enclosures
- H05K7/20136—Forced ventilation, e.g. by fans
- H05K7/20154—Heat dissipaters coupled to components
- H05K7/20163—Heat dissipaters coupled to components the components being isolated from air flow, e.g. hollow heat sinks, wind tunnels or funnels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F5/00—Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
- B22F2005/005—Article surface comprising protrusions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
- B23P2700/00—Indexing scheme relating to the articles being treated, e.g. manufactured, repaired, assembled, connected or other operations covered in the subgroups
- B23P2700/10—Heat sinks
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28D—HEAT-EXCHANGE APPARATUS, NOT PROVIDED FOR IN ANOTHER SUBCLASS, IN WHICH THE HEAT-EXCHANGE MEDIA DO NOT COME INTO DIRECT CONTACT
- F28D21/00—Heat-exchange apparatus not covered by any of the groups F28D1/00 - F28D20/00
- F28D2021/0019—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for
- F28D2021/0028—Other heat exchangers for particular applications; Heat exchange systems not otherwise provided for for cooling heat generating elements, e.g. for cooling electronic components or electric devices
- F28D2021/0029—Heat sinks
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F28—HEAT EXCHANGE IN GENERAL
- F28F—DETAILS OF HEAT-EXCHANGE AND HEAT-TRANSFER APPARATUS, OF GENERAL APPLICATION
- F28F2255/00—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes
- F28F2255/18—Heat exchanger elements made of materials having special features or resulting from particular manufacturing processes sintered
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/25—Process efficiency
Definitions
- the present disclosure relates generally to a heat sink for conveying heat from a baseplate to a cover. More specifically, it relates to a heat sink produced by additive manufacturing.
- Heat skinks are used to convey heat away from a heat source, such as an electronic device, to prevent the heat source and/or other components from being damaged due to excessive temperatures.
- a heat source such as an electronic device
- One type of heat skink that is conventionally known is a heat pipe, which uses a refrigerant fluid that changes from a liquid to a gas at an evaporator to transmit heat from the heat source to a condenser, where heat exits as the refrigerant fluid condenses back to a liquid.
- Conventional heat pipes employ a wick to transfer the condensed refrigerant from the condenser back to the evaporator.
- Additive manufacturing is used to manufacture parts in a series of steps by progressively adding material to the part being manufactured.
- One type of conventional additive manufacturing uses a heat source, such as a laser, to melt a source material, such as a metal powder.
- a source material such as a metal powder.
- the source material is removed from areas where it is not melted. This allows parts to be made with a variety of complex shapes.
- a heat sink including a baseplate of thermally-conductive material defining a lower surface for conducting heat from a heat source.
- the heat sink also includes a radiator disposed upon the baseplate away from the lower surface.
- the radiator includes a skin of melted material formed by additive manufacturing and enclosing a chamber.
- An outer wick of porous material is disposed within the chamber, the outer wick coats an inner surface of the skin.
- the outer wick has a physical property that varies over a distance from the baseplate.
- a method of forming a heat sink comprises: selectively melting a source material to form a skin defining a chamber of a radiator; forming the source material to define an outer wick of porous material within the chamber coating an inner surface of the skin; and attaching a baseplate of thermally- conductive material to the radiator to enclose the chamber, wherein the baseplate is configured to be in thermal communication with a heat source.
- the outer wick of porous material defines a physical property that varies as a function of distance from the baseplate.
- FIG. 1 is a side cut-away view of a heat sink according to some embodiments of the present disclosure
- FIG. 2 is a side cut-away view of a heat sink according to some embodiments of the present disclosure
- FIG. 3 is a side cut-away view of a heat sink according to some embodiments of the present disclosure
- FIG. 4A is a side cut-away view of a heat sink according to some embodiments of the present disclosure
- FIG. 4B is an enlarged view of a portion of FIG. 4A;
- FIG. 5 A is a side view of a heat sink according to some embodiments of the present disclosure.
- FIG. 5B is a cross-sectional view of the heat sink of FIG. 5 A through section
- FIG. 5C is a cross-sectional view of the heat sink of FIG. 5 A through section
- FIG. 6A is a top view of a heat sink according to some embodiments of the present disclosure.
- FIG. 6B is a cross-sectional view of the heat sink of FIG. 6A through section
- FIG. 6C is a cross-sectional view of the heat sink of FIG. 6A through section
- FIG. 7 is a cut-away perspective view of a heat sink according to some embodiments of the present disclosure.
- FIG. 8 is a perspective view of a heat sink according to some embodiments of the present disclosure.
- Figure 9 is a flow chart listing steps in a method of forming a heat sink.
- Figure 10 is a flow chart listing steps in a method of dissipating heat by a heat sink.
- FIG. 1 shows a first example heat sink 20 that includes a baseplate 22 of thermally-conductive material for conducting heat from a heat source.
- the baseplate 22 is shaped as a flat plate extending between a lower surface 24 and an upper surface 25.
- the lower surface 24 of the baseplate 22 is configured to be in thermal communication with a heat source, such as an integrated circuit or a power electronic device.
- the heat sink 20, 120, 220 also includes a radiator 26 disposed upon the upper surface 25 of the baseplate 22, away from the lower surface 24 for transferring heat to atmosphere, such as air or liquid that surrounds the radiator 26.
- the radiator 26 may transfer heat to the atmosphere by any means such as radiation, conduction, and/or convection.
- the radiator 26 includes a skin 32 of melted material formed by additive manufacturing, with the skin 32 and enclosing a chamber 36.
- the skin 32 may be formed by selectively melting a source material, such as a loose powder, using a concentrated heat source, such as a laser.
- the heat sink 20, 120, 220 also includes an outer wick 38 of porous material disposed within the chamber 36 and coating an inner surface 34 of the skin 32.
- the outer wick 38 is permeable to liquid, allowing liquid and/or gases to flow therethrough with relatively low restrictions to flow.
- the outer wick 38 comprises a permeable filling including loose granules 40 disposed within the chamber 36.
- the permeable filling may completely fill the chamber 36 as shown in FIGS. 1-2. Alternatively, the permeable filling may only partially fill the chamber 36.
- the loose granules 40 define void spaces 42 therebetween.
- the permeable filling may be, for example, a loose powder or a porous solid.
- the permeable filling includes the source material in an unmelted state.
- an outermost area of the source material may be melted to form the skin 32, and source material located therein may be left in an unmelted state or in a semi-melted state to form the permeable filling.
- the permeable filling may be entirely comprised of the source material.
- the permeable filling may include the source material with one or more other components, which may be added after the skin 32 is formed by the additive manufacturing process.
- the permeable filling may include none of the source material.
- the permeable filling may be entirely made of material that is added after the skin 32 is formed by the additive manufacturing process.
- the permeable filling is permeable to liquid flow, allowing a liquid or a gas to pass therethrough.
- the permeable filling could include other structural components, such as, for example, a lattice or a foam or a compacted solid of granules with void spaces 42 therebetween.
- the permeable filling may comprise a combination of loose granules and another liquid-permeable material such as a lattice or a foam or a compacted solid.
- the permeable filling preferably functions as a porous wick, promoting capillary action to convey liquid therethrough.
- the permeable filling provides the heat sink 20, 120, 220 with structural rigidity, which may counteract air pressure force on the baseplate 22, the cover 30, and/or the skin 32. This may be especially useful in embodiments where the chamber 36 is under a vacuum.
- the radiator 26 includes a foundation 28 that extends between the baseplate 22 and a cover 30 that is spaced apart from the baseplate 22.
- One or both of the baseplate 22 and/or the cover 30 may be made by melting the source material by additive manufacturing.
- the baseplate 22 and/or the cover 30 may be made independently and/or by a different process, such as by stamping, casting, machining, etc.
- all or part of the skin 32 forms the cover 30.
- the cover 30 is generally flat and is parallel and spaced apart from the baseplate 22. However, the cover 30 may have different shapes or orientations, depending on packaging requirements and/or heat dissipation requirements.
- the foundation 28 may be hollow, defining the chamber 36 therein. In some embodiments, the foundation 28 may be partially or completely filled with material.
- a refrigerant 50 is disposed within the chamber 36.
- the refrigerant 50 may be free to flow through the outer wick 38.
- the outer wick 38 may hold the refrigerant 50 near the skin 32, thereby improving the ability of the heat sink 20, 120, 220 to dissipate heat.
- the refrigerant 50 may boil, or change between a liquid phase 52 and a vapor phase 54 to convey heat from the baseplate 22 to the cover 30.
- the refrigerant 50 may boil from a first region 56 proximate to the baseplate 22 and travel in the vapor phase 54 to a second region 58 proximate to the cover 30.
- the refrigerant 50 may condense back to the liquid phase 52.
- the refrigerant 50 in the liquid phase 52 may be conveyed through the void spaces 42 within the loose granules 40 and back to the first region 56 proximate to the baseplate 22 by capillary action.
- the radiator 26 includes a plurality of fins 60 extending away from the baseplate 22. More specifically, the cover 30 may extend in a generally flat plane, with the plurality of fins 60 extending generally transversely to the generally flat plane. The cover 30 could define one or more curved surfaces, which may or may not include the fins 60 extending therefrom.
- the fins 60 may be formed as pillars or posts. Alternatively or additionally, the fins 60 may be formed as ribs that extend for a substantial length along the cover 30.
- the fins 60 may function to increase the surface area of the skin 32 to promote heat transfer to a fluid, such as a gas or a liquid, contacting an outer surface of the skin 32 opposite the chamber 36.
- the fins 60 is solid. In some other embodiments, and as shown in FIG. 2, the outer wick 38 extends into the fins 60. In some embodiments, and as shown for example in FIG. 2, the fins 60 are filled with the permeable material, which may be in fluid communication with the permeable material within the foundation 28. In this way, the refrigerant 50, in the vapor phase 54, can travel into the fins 60 to reach the second region 58, which is sufficiently cold to cause the vapor 54 to condense back to the liquid phase 52.
- FIGS. 3-4, 5A-5C, 6A-6C, and 7 show a second example heat sink 120.
- the second example heat sink 120 is similar to the first example heat sink 20, with some additional design features.
- the radiator 26 is formed as a monolithic piece by additive manufacturing.
- the second example heat sink 120 includes an outer wick 38 of porous material disposed within the chamber and coating an inner surface 34 of the skin 32.
- the outer wick 38 comprises material melted or partially melted material by additive manufacturing.
- the second example heat sink 120 shown in FIGS. 3-7 includes a plurality of fins 60 extending away from the baseplate 22.
- At least one of the fins 60 comprises a body 62 shaped as a rod or a cone extending away from the baseplate 22 to a closed top 64.
- the body 62 of one of the fins 60 may be shaped as a cylinder that extends for an entire length between the cover 30 and the closed top 64.
- the body 62 of one of the fins 60 may taper down from a first cross- sectional area at the cover 30 to a second, smaller cross-sectional area at the closed top 64.
- the heat sink 20, 120, 220 includes an inner wick 66 of porous material disposed within the chamber 36 and coating the upper surface 25 of the baseplate 22.
- the inner wick 66 may be integrally formed with the baseplate 22, for example as a monolithic piece. Alternatively, the inner wick 66 may be formed separately from the baseplate 22.
- the heat sink 20, 120, 220 includes an intermediate wick 68 of porous material disposed within the chamber 36 between the outer wick 38 and the inner wick 66 for conveying liquid therebetween.
- the radiator 26 defines a cavity 70 that extends between the inner wick 66 adjacent to the baseplate 22 into the fins 60. The cavity 70 may extend up into the closed top 64 of the fins 60.
- the vapor phase 54 of the refrigerant 50 may travel through the cavity 70 from the inner wick 66 and into the fins 60, where it condenses into the liquid phase 52.
- the liquid phase 52 of the refrigerant may condense within the outer wick 38 and return to the inner wick 66 via the intermediate wick 68 by gravity and/or by capillary action.
- any or all of the wicks 38, 66, 68 may be formed by additive manufacturing
- each of the wicks 38, 66, 68 may be formed together with the skin 32 from shared source material.
- a first melting power and/or speed may be used to create the skin 32, which impermeable, and a second, lower melting power and/or a higher speed may be used to create any or all of the wicks 38, 66, 68, which are permeable to liquid flow.
- paths used in the AM process between adjacent layers may be rotated to form an open lattice type structure within one or more of the wicks 38, 66, 68.
- the baseplate 22 may comprise a solid piece of material, such as metal.
- the baseplate may comprise an insulated metal substrate (IMS) printed circuit board, such as ThermalClad by Henkel.
- IMS insulated metal substrate
- the baseplate 22 may be attached to the radiator 26 after the radiator 26 is formed. In some embodiments, unmelted source material may be removed from the radiator 26 prior to attaching the baseplate 22 thereto, thus forming the cavity 70 within the radiator 26.
- the baseplate 22 may be welded to the radiator 26 to hermetically seal the chamber 36. Alternatively or additionally, the baseplate 22 may be attached to the radiator 26 by other means such as using an adhesive and/or using one or more fasteners.
- FIGS. 4A-4B show a side cut-away view of a heat sink 120 with an outer wick 38 having one or more physical properties that vary over distance from the baseplate 22.
- the heat sink 120 may be partially or completely filled with source material 33 in a partially-melted and/or in an unmelted state. Such unmelted source material may be called “green” powder. The unmelted source material 33 may further enhance heat transfer from the baseplate 22 to the skin 32.
- FIG. 4B is an enlarged sectional view of a portion of FIG. 4A.
- one or more of the physical properties may vary in discrete steps. Alternatively or additionally, one or more of the physical properties may vary continuously over distance from the baseplate 22. For example, a thickness t of the outer wick 38 may vary in discrete steps, linearly, exponentially, or in some other function of distance.
- the one or more physical properties includes a porosity p that varies over distance. Specifically, FIG.
- FIG. 4B shows an embodiment having a first porosity pi in a first region, a second porosity pi in a second region located between the first region and the baseplate 22, and a third porosity pi in a third region that is located between the second region and the baseplate 22.
- the one or more physical properties includes a thickness t that varies over distance.
- the outer wick 38 may vary between a first thickness ti at a first location spaced away from the baseplate 22, and a second thickness 3 ⁇ 4 at a second location that is between the first location and the baseplate 22, and a third thickness i ? at a third location that is between the second location and the baseplate 22.
- the thickness t of the outer wick 38 may vary between a larger value closer to the baseplate 22 and a smaller value farther away from the heat source 10.
- the one or more varying physical properties of the outer wick 38 may include other properties, such as composition, size, and/or shape of grains of material that comprise the outer wick 38, or size and/or shape of structural features, such as cells in a structure that comprises the outer wick 38, or any other physical property of the outer wick
- FIGS. 5A-5C, FIGS. 6A-6C, and FIG. 7 show various views of the second example heat sink 120.
- the baseplate 22 has a square-shaped footprint of 100 mm x 100 mm.
- the baseplate 22 may have other shapes, which may depend on application requirements.
- the baseplate 22 may be smaller or larger than 100 mm x 100 mm.
- each of the fins 60 may have a circular cross-section with a diameter of 15 mm.
- the fins 60 may have different shapes and/or sizes, which may be regular or irregular. In other words, different fins 60 on one heat sink 20, 120, 220 may have different shapes or sizes.
- the heat sink 20, 120, 220 may have a total height of 75 mm, however, the heat sink 20, 120, 220 may be smaller or larger than 75 mm in height.
- the foundation 28 may have a height of 25 mm between the lower surface 24 of the baseplate 22 and the cover 30. However, the foundation 28 may have a height that is less than or greater than 25 mm.
- FIG. 8 shows a third example heat sink 220, which is similar to the second example heat sink 120.
- the third example heat sink 220 includes sixty-four fins 60 arranged in an 8x8 pattern.
- Each of the fins 60 of the third example heat sink 220 have a conical shape, with the body 62 tapering from a first cross-sectional area at the foundation 28 to a second, smaller cross-sectional area at the closed top 64.
- the method 100 includes 102 selectively melting a source material to form a skin 32 defining a chamber 36 of a radiator 26.
- the source material may be selectively melted using a laser.
- the method 100 also includes 104 forming the source material to define an outer wick 38 of porous material within the chamber coating an inner surface 34 of the skin 32.
- Forming the outer wick 38 may comprise melting the source material, which may be performed as part of the same additive manufacturing process used to form the skin 32.
- this step 104 of melting the source material to define the outer wick 38 is performed using an energy source having an intensity that is lower than an intensity used to selectively melt the source material to form the skin 32.
- step 104 of forming the source material to define an outer wick 38 of porous material includes varying one or more physical properties of the outer wick 38 of porous material. Varying the one or more physical properties in this step 104 may include for example, varying the process of forming the source material to define the outer wick 38, for example, using different energy levels and/or different patterns. Alternatively or additionally, varying the one or more physical properties may include varying the source material. For example, source materials having different compositions and/or different physical properties, such as grain size, may be used to form different levels of the outer wick 38.
- the one or more physical properties may be varied as a function of distance from a given location, such as a surface of the outer wick 38 to receive a baseplate 22.
- the one or more physical properties may include, for example, a thickness and/or a porosity of the outer wick 38.
- the one or more physical properties may include a grain size of the porous material and/or another physical property, such as cell size or shape of the porous material.
- the one or more physical properties may be varied in two or more discrete steps.
- the one or more physical properties may be varied continuously as a function of distance.
- the thickness may be varied at a constant rate or at a changing rate between a first thickness and a different second thickness over a distance.
- the method 100 also includes 106 attaching a baseplate of 22 thermally - conductive material to the radiator 26 to enclose the chamber 36, wherein the baseplate 22 is configured to be in thermal communication with a heat source 10. Attaching the baseplate 22 may include forming a hermetic seal enclosing the chamber 36. The baseplate 22 may be welded to the radiator 26. Alternatively or additionally, the baseplate 22 may be attached to the radiator 26 by other means such as using an adhesive and/or using one or more fasteners.
- the method 100 also includes 108 removing excess source material from the chamber 36 to define a cavity 70.
- the excess source material may be, for example, “green” powder that was not solidified by the additive manufacturing process.
- the excess source material may be removed from the chamber 36 prior to attaching the baseplate of 22.
- the excess source material may be removed from a bottom surface of the radiator 26, with the baseplate of 22 subsequently covering that bottom surface to enclose the chamber 36.
- the excess source material may be removed from a hole through the skin 32 of the radiator 26.
- a hole may be drilled through the skin 32 for draining the excess source material from the chamber 36 of the radiator 26. Such a hole may be plugged or filled after the excess material is removed.
- the source material from the additive manufacturing process may be removed from the chamber 36, for example by suction or by shaking it out of one or more holes in the baseplate 22 and/or the skin 32. Additional material may be added into the chamber 36 to comprise the permeable filling.
- the amount and/or the composition of the permeable filling within the chamber 36 may be selected to optimize wicking of the refrigerant 50. Alternatively or additionally, the amount and/or the composition of the permeable filling within the chamber 36 may be selected to provide structural rigidity to the heat sink 20, 120, 220, and particularly to counteract air pressure where the chamber 36 contains a vacuum.
- the method 100 of forming the heat sink 20, 120, 220 may further include 110 evacuating air from the chamber 36. This step may be unnecessary if, for example, the chamber 36 is formed in a vacuum, so that it contains little to no air in the first place.
- the method 100 of forming the heat sink 20, 120, 220 may further include 112 adding a refrigerant 50 into the chamber 36; and 114 sealing the chamber 36 after adding the refrigerant 50 into the chamber 36.
- Sealing the chamber 36 may be performed by attaching the baseplate 22 to the radiator 26 and/or by fixing a cap or a plug to cover a passage into the chamber 36, where the passage is used at an earlier stage for adding the refrigerant 50 into the chamber 36, and/or for evacuating air from the chamber 36.
- a passage may be formed as part of the additive manufacturing process.
- the passage may be formed, for example by drilling or puncturing, after the chamber 36 is formed.
- the passage may be integrally formed in the baseplate 22 before the skin 32 is formed.
- the method 100 of forming the heat sink 20 may further include 116 forming an inner wick 66 of porous material coating an upper surface 25 of the baseplate 22. In some embodiments, the method 100 of forming the heat sink 20 may further include 118 forming an intermediate wick 68 of porous material disposed within the chamber 36 between the outer wick 38 and the inner wick 66 for conveying liquid therebetween. [0050] As described in the flow chart of FIG. 10, a method 200 of dissipating heat by a heat sink 20, 120, 220 is also provided.
- the method 200 of dissipating heat by the heat sink 20 includes 202 evaporating a refrigerant 50 from a first region 56 proximate to a baseplate 22 to a gaseous state, also called a vapor phase 54.
- the method 200 of dissipating heat by the heat sink 20, 120, 220 also includes 204 condensing the refrigerant 50 from the gaseous state to a liquid state, also called a liquid phase 52, at a second region 58 proximate to a skin 32 of a radiator 26.
- the method 200 of dissipating heat by the heat sink 20, 120, 220 proceeds with 206 conveying the refrigerant 50 in the liquid phase 52 from the second region 58 to the first region 56.
- the step of 206 conveying the refrigerant 50 in the liquid phase 52 is performed, at least in part, by capillary action through one or more wicks 38, 66, 68.
- the step of 206 conveying the refrigerant 50 in the liquid phase 52 may be performed, at least in part, by gravity.
- the heat sink 20, 120, 220 may have a preferred orientation in which it is most effective to remove heat from the baseplate 22.
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Physics & Mathematics (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Thermal Sciences (AREA)
- General Engineering & Computer Science (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Life Sciences & Earth Sciences (AREA)
- Sustainable Development (AREA)
- Condensed Matter Physics & Semiconductors (AREA)
- General Physics & Mathematics (AREA)
- Computer Hardware Design (AREA)
- Power Engineering (AREA)
- Composite Materials (AREA)
- Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)
- Cooling Or The Like Of Electrical Apparatus (AREA)
Abstract
Description
Claims
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US202062975549P | 2020-02-12 | 2020-02-12 | |
PCT/US2021/017642 WO2021163312A1 (en) | 2020-02-12 | 2021-02-11 | Additive manufactured heat sink |
Publications (2)
Publication Number | Publication Date |
---|---|
EP4085738A1 true EP4085738A1 (en) | 2022-11-09 |
EP4085738A4 EP4085738A4 (en) | 2023-07-05 |
Family
ID=77291648
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP21754223.2A Withdrawn EP4085738A4 (en) | 2020-02-12 | 2021-02-11 | Additive manufactured heat sink |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP4085738A4 (en) |
KR (1) | KR20220139934A (en) |
CN (1) | CN115088400A (en) |
CA (1) | CA3166553A1 (en) |
WO (1) | WO2021163312A1 (en) |
Family Cites Families (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6237223B1 (en) * | 1999-05-06 | 2001-05-29 | Chip Coolers, Inc. | Method of forming a phase change heat sink |
US20040011509A1 (en) * | 2002-05-15 | 2004-01-22 | Wing Ming Siu | Vapor augmented heatsink with multi-wick structure |
CN101754656B (en) * | 2008-12-10 | 2013-02-20 | 富准精密工业(深圳)有限公司 | Uniform temperature plate |
US10660236B2 (en) * | 2014-04-08 | 2020-05-19 | General Electric Company | Systems and methods for using additive manufacturing for thermal management |
US10356945B2 (en) * | 2015-01-08 | 2019-07-16 | General Electric Company | System and method for thermal management using vapor chamber |
GB201509580D0 (en) * | 2015-06-03 | 2015-07-15 | Rolls Royce Plc | Manufacture of component with cavity |
EP3279597B1 (en) | 2016-08-04 | 2022-09-28 | General Electric Company | METHOD FOR MANUFACTURING A SYSTEM FOR THERMAL
MANAGEMENT USING VAPOR CHAMBER |
US20190082560A1 (en) | 2017-09-08 | 2019-03-14 | Toyota Motor Engineering & Manufacturing North America, Inc. | Systems and methods for additive manufacturing of wick structure for vapor chamber |
EP3584527B1 (en) * | 2018-06-19 | 2021-08-11 | Nokia Technologies Oy | Heat transfer apparatus |
-
2021
- 2021-02-11 CA CA3166553A patent/CA3166553A1/en active Pending
- 2021-02-11 KR KR1020227030857A patent/KR20220139934A/en unknown
- 2021-02-11 WO PCT/US2021/017642 patent/WO2021163312A1/en unknown
- 2021-02-11 CN CN202180014091.2A patent/CN115088400A/en active Pending
- 2021-02-11 EP EP21754223.2A patent/EP4085738A4/en not_active Withdrawn
Also Published As
Publication number | Publication date |
---|---|
WO2021163312A1 (en) | 2021-08-19 |
CN115088400A (en) | 2022-09-20 |
CA3166553A1 (en) | 2021-08-19 |
EP4085738A4 (en) | 2023-07-05 |
KR20220139934A (en) | 2022-10-17 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US7013958B2 (en) | Sintered grooved wick with particle web | |
US7814655B2 (en) | Heat sink in the form of a heat pipe and process for manufacturing such a heat sink | |
US20210307202A1 (en) | Additive manufactured heat sink | |
US8047269B2 (en) | Thermal spreader for simultaneously enhancing capillary effect and structural strength | |
US6938680B2 (en) | Tower heat sink with sintered grooved wick | |
US6880626B2 (en) | Vapor chamber with sintered grooved wick | |
US7028759B2 (en) | Heat transfer device and method of making same | |
US10514211B2 (en) | Vapor chamber | |
US7913748B2 (en) | Vapor chamber | |
US20110000649A1 (en) | Heat sink device | |
US20050051307A1 (en) | Integrated circuit heat pipe heat spreader with through mounting holes | |
US20120170221A1 (en) | Compliant vapor chamber chip packaging | |
US8356410B2 (en) | Heat pipe dissipating system and method | |
US10495387B2 (en) | Multi-layer wick structures with surface enhancement and fabrication methods | |
WO2005006395A2 (en) | Heat transfer device and method of making same | |
WO2020123683A1 (en) | Additive manufactured heat sink | |
EP4085738A1 (en) | Additive manufactured heat sink | |
US20110290451A1 (en) | Heat cooler | |
WO2023204919A1 (en) | Surface mount wicking structure |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE INTERNATIONAL PUBLICATION HAS BEEN MADE |
|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: REQUEST FOR EXAMINATION WAS MADE |
|
17P | Request for examination filed |
Effective date: 20220801 |
|
AK | Designated contracting states |
Kind code of ref document: A1 Designated state(s): AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC MK MT NL NO PL PT RO RS SE SI SK SM TR |
|
DAV | Request for validation of the european patent (deleted) | ||
DAX | Request for extension of the european patent (deleted) | ||
P01 | Opt-out of the competence of the unified patent court (upc) registered |
Effective date: 20230517 |
|
A4 | Supplementary search report drawn up and despatched |
Effective date: 20230606 |
|
RIC1 | Information provided on ipc code assigned before grant |
Ipc: B22F 7/08 20060101ALI20230531BHEP Ipc: B22F 7/06 20060101ALI20230531BHEP Ipc: B33Y 80/00 20150101ALI20230531BHEP Ipc: B33Y 10/00 20150101ALI20230531BHEP Ipc: B23P 15/26 20060101ALI20230531BHEP Ipc: B22F 3/11 20060101ALI20230531BHEP Ipc: H05K 7/20 20060101AFI20230531BHEP |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: THE APPLICATION HAS BEEN WITHDRAWN |
|
18W | Application withdrawn |
Effective date: 20231016 |