WO2024077925A1 - 一种折弯异型超薄均热板及其制造工艺和应用 - Google Patents

一种折弯异型超薄均热板及其制造工艺和应用 Download PDF

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WO2024077925A1
WO2024077925A1 PCT/CN2023/090429 CN2023090429W WO2024077925A1 WO 2024077925 A1 WO2024077925 A1 WO 2024077925A1 CN 2023090429 W CN2023090429 W CN 2023090429W WO 2024077925 A1 WO2024077925 A1 WO 2024077925A1
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ultra
thin
vapor chamber
heat spreader
manufacturing process
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PCT/CN2023/090429
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English (en)
French (fr)
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尹树彬
汤勇
黄皓熠
张仕伟
赵威
黎洪铭
黄梓滨
余小媚
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广东畅能达科技发展有限公司
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Publication of WO2024077925A1 publication Critical patent/WO2024077925A1/zh

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    • 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
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • 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
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/50—Glass production, e.g. reusing waste heat during processing or shaping
    • Y02P40/57—Improving the yield, e-g- reduction of reject rates

Definitions

  • the invention relates to the technical field of vapor chamber manufacturing, and in particular to a manufacturing process of a bent special-shaped ultra-thin vapor chamber and the manufactured vapor chamber.
  • Phase change thermal control technology is increasingly used in all walks of life, providing a stable thermal environment for all kinds of electronic equipment.
  • ultra-thin heat spreaders play an important role in constructing an additional heat channel between the motor stator winding and the cooling case. Due to the large distance between the stator winding of the drive motor and the cooling case, the thickness of the existing phase change thermal control device still does not meet the requirement of completely filling the gap. Therefore, it is reasonable and feasible to construct an additional heat channel between the stator winding and the cooling case by bending. The bending structure is an important factor affecting the heat transfer performance of the ultra-thin heat spreader. Whether the problem of failure of the ultra-thin heat spreader after bending can be effectively solved becomes the key to whether the motor can increase the maximum power and achieve lightweight.
  • the existing manufacturing process can only achieve the non-failure of cylindrical heat pipes after bending.
  • the manufacturing process of bending special-shaped ultra-thin heat spreaders is not yet mature, and the ultra-thin heat spreaders are prone to failure after bending.
  • the failure is mainly caused by the cracking of the shell surface during the bending process and the collapse and blockage of the airway.
  • the present invention proposes a manufacturing process of a bent special-shaped ultra-thin vapor chamber and the manufactured vapor chamber, wherein the manufacturing process significantly reduces the failure rate of the bent special-shaped ultra-thin vapor chamber.
  • the present invention adopts the following technical solutions to achieve the above problems:
  • a manufacturing process of a bent special-shaped ultra-thin vapor chamber comprises the following steps:
  • wick material Use a laser marking machine to shape the sintered metal mesh and use The cutting machine cuts the metal braids of the corresponding quantity and size as the shell plate; of course, if the production cost needs to be reduced based on cost considerations, the ultra-thin heat spreader can only have a metal mesh or only a metal braid.
  • the laser generator of the laser marking machine generates a high-energy continuous laser beam.
  • the focused laser acts on the substrate, causing the surface material to melt instantly or even vaporize.
  • the required graphic mark is formed.
  • the laser marking machine is characterized by non-contact processing. It can mark on any special-shaped surface. The workpiece will not deform or generate internal stress. It is suitable for marking materials such as metal, plastic, glass, ceramic, wood, leather, etc. Therefore, we first draw the shape of the metal mesh on CAD, and then import it into the program of the laser marking machine to finalize the metal mesh.
  • Preparation of liquid wick chemically corrode the prepared metal mesh and metal braid.
  • the treated metal mesh and metal braid will have good capillary properties.
  • the materials of the metal mesh and metal braid are the common materials of ultra-thin heat spreaders on the market; the chemical corrosion liquid is the corrosive liquid used on the market, which can form a microstructure with capillary properties on the metal mesh and metal braid.
  • Commonly used metal mesh and metal braid are mainly copper metal.
  • the treated metal wire mesh and metal braided belt on the shell plate of the soaking plate, and sinter them with 650°C reducing gas.
  • the sintered metal wire mesh and metal braided belt should be welded to the shell plate as a whole.
  • the reducing gas is nitrogen-hydrogen mixed gas, 95% nitrogen + 5% hydrogen.
  • the bending radius of the neutral layer is R10, and the bending angle is 140.99°;
  • the present invention can significantly improve the heat dissipation of the winding at the overhang, reduce the temperature of the motor winding, increase the rated power of the motor, and achieve lightweight and miniaturization of the motor.
  • the present invention uses industrialized production and has low cost.
  • the preparation process of the present invention is simple to operate, convenient and practical.
  • the present invention has a simple structure and has low assembly requirements.
  • the present invention does not require high precision for the devices and parts involved in production and is easy to process.
  • FIG1 is a schematic diagram of the bending of an ultra-thin vapor chamber
  • FIG2 is a diagram showing the ultra-thin heat spreader after bending
  • FIG. 3 is a schematic diagram of the installation of the ultra-thin heat spreader in the motor.
  • a manufacturing process of a bent special-shaped ultra-thin vapor chamber comprises the following steps:
  • Preparation of liquid wick chemically corrode the prepared metal mesh and metal braid.
  • the treated metal mesh and metal braid will have good capillary properties.
  • the materials of the metal mesh and metal braid are the common materials of ultra-thin heat spreaders on the market; the chemical corrosion liquid is the corrosive liquid used on the market, which can form a microstructure with capillary properties on the metal mesh and metal braid.
  • Commonly used metal mesh and metal braid are mainly copper metal.
  • the treated metal wire mesh and metal braided belt on the shell plate of the soaking plate, and sinter them with 650°C reducing gas.
  • the sintered metal wire mesh and metal braided belt should be welded to the shell plate as a whole.
  • the reducing gas is nitrogen-hydrogen mixed gas, 95% nitrogen + 5% hydrogen.
  • the bending radius of the neutral layer of the ultra-thin heat sink bending section is R10, and the bending angle is 140.99°;
  • the center distance between two adjacent support pillars is 250%-400% of the support pillar radius.
  • the support pillar radius is 0.5 mm, and the center distance is set at 2 mm.
  • the shell thickness in this embodiment is preferably 0.2-2 mm.
  • the efficiency of the ultra-thin heat spreader prepared by the above manufacturing process can reach more than 90% after bending, which greatly saves costs. At the same time, it can greatly improve the heat dissipation efficiency of the motor winding when used in the motor.
  • the ultra-thin heat spreader manufactured by the manufacturing process of Example 1 is shown in FIG2 and is used in liquid-cooled or air-cooled motors as a phase change thermal control device between the motor stator winding and the cooling housing, as shown in FIG3.
  • the ultra-thin heat spreader is folded into a wave shape, with the upper wave top close to the cooling housing and the lower wave bottom in contact with the overhanging winding of the motor stator, thereby providing an additional heat dissipation path for the motor winding. This is the installation position of the ultra-thin heat spreader in the motor, so the motor cooling casing is not drawn.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Power Engineering (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Molds, Cores, And Manufacturing Methods Thereof (AREA)

Abstract

一种折弯异型超薄均热板及其制造工艺和应用，该制造工艺包括清洗上、下壳板并干燥；准备吸液芯材料并制作吸液芯；将吸液芯与壳板进行烧结处理；对壳板自动涂上高温焊膏；将上壳板与下壳板组装合并后进行高温烧结，并将灌液管插入注液口中焊接，焊接完成后对超薄均热板进行灌液处理，灌液完成后将其放置于低于-8℃的乙醇中进行工质冻结；继续进行抽真空处理和进行不凝性气体去除处理，接着进行封口处理；采用折弯用凹凸模具或弯管机对测试通过的超薄均热板进行折弯处理。该方法操作简单，制备得到的超薄均热板能显著改善悬伸处绕组的散热情况，提升电机额定使用功率，实现电机轻量化和微型化。

Description

一种折弯异型超薄均热板及其制造工艺和应用 技术领域
本发明涉及均热板制造技术领域，具体涉及一种折弯异型超薄均热板的制造工艺及制得的均热板。
背景技术
相变热控技术越来越多地应用在各行各业，为各类电子设备提供稳定的热环境。目前，超薄均热板在构建电机定子绕组-冷却机壳额外热通道的散热方式上扮演着重要角色。由于驱动电机定子绕组与冷却机壳间的距离较大，现有的相变热控器件厚度仍达不到完全填充间隙的要求，因此，通过折弯的方式来构建定子绕组与冷却机壳间的额外热通道是合理且可行的。折弯结构是影响超薄均热板传热性能的重要因素，能否有效解决超薄均热板折弯后失效的问题成为电机能否提升极限功率，实现轻量化的关键。
然而，现有的制造工艺仅能实现圆柱形热管折弯后不失效，对折弯异型超薄均热板的制造工艺尚未成熟，极易出现折弯后的超薄均热板失效问题。通过对超薄均热板折弯失效原因的分析，主要是折弯过程中壳板表面破裂，以及气道塌陷堵塞导致的失效。
发明内容
有鉴于此，本发明提出了一种折弯异型超薄均热板的制造工艺及制得的均热板，该工艺显著降低折弯异型超薄均热板的失效率。
为解决上述技术问题，本发明采用以下技术方案予以实现：
一种折弯异型超薄均热板的制造工艺，包括如下步骤：
1、采用超声波清洗机将生产均热板的上、下壳板浸没在无水乙醇中清洗1-5min，再使用吹风机/烤箱/自然风干等方式对其进行干燥处理。
2、制备吸液芯材料：采用激光打标机对烧结好的金属丝网定型，并使用 裁切机裁剪与壳板对应数量及尺寸的金属编织带；当然，如果基于成本考虑需要降低生产成本，超薄均热板中可以只有金属丝网或者只有金属编织带。
激光打标机的激光发生器生成高能量的连续激光光束，聚焦后的激光作用于承印材料，使表面材料瞬间熔融，甚至气化，通过控制激光在材料表面的路径，从而形成需要的图文标记。激光打标机的特点是非接触加工，可在任何异型表面标刻，工件不会变形和产生内应力，适于金属、塑料、玻璃、陶瓷、木材、皮革等材料的标记。因此我们首先在CAD上进行金属丝网形状的绘制，再导入到激光打标机的程序里进行金属丝网的定型。
3、吸液芯制备：对准备好的金属丝网与金属编织带进行化学腐蚀处理，处理过后的金属丝网与金属编织带将具有良好的毛细性能。金属丝网与金属编织带的材料选用市场上超薄均热板的常用材料；化学腐蚀用到的药液为市面上用到的腐蚀药液，其以能在金属丝网与金属编织带上形成具有毛细性能的微结构。常用的金属丝网和金属编织带主要为铜金属。
4、将处理好的金属丝网和金属编织带铺放于均热板的壳板上，使用650℃的还原气体对其进行烧结处理，烧结过后的金属丝网与金属编织带应与壳板焊接为一体。还原气体具体是氮氢混合气，95％氮气+5％氢气。
5、采用冲压机对烧结好金属丝网及编织带的壳板冲注液口，接着采用点胶机对壳板自动涂上熔点630℃的高温焊膏。
6、将上壳板与下壳板组装合并后放置于清洁干净的石墨模具中固定，为了保证焊接的成功率，需要在石墨模具的顶部加1-20kg不等的配重(一般为铁块)，配重由壳板厚度、点胶量等因素决定。
7、再次使用650℃的还原气体对组装好的均热板进行高温烧结，烧结完成后将灌液管插入步骤5中冲压形成的注液口中，并采用高频感应焊机进行焊接。
8、焊接完成后，采用真空抽注泵对超薄均热板进行验漏，若压力低于1Pa则视为验漏通过。
9、采用注射器对验漏通过后的超薄均热板进行灌液处理，灌液完成后将 其放置于低于-8℃的乙醇中进行工质冻结，冻结时间大于5mi n。
10、再次采用真空抽注泵对内部工质冻结完成的超薄均热板进行抽真空处理，直至小于3Pa。
11、采用加热平台对抽真空后的超薄均热板除掉不凝性气体，接着采用液压钳对其进行封口处理，并使用工业胶对其进行二次封口。
12、采用电阻焊机将封口后的超薄均热板的注液管作去尾处理，并置于60℃水浴进行启动性能测试。
13、采用折弯用凹凸模具或弯管机对测试通过的超薄均热板进行折弯处理，并对折弯后的超薄均热板进行二次启动性能测试，以检验其折弯后是否失效。
本发明中，为了使折弯后的超薄均热板仍然有效，可从以下关键点着手：
(1)增大折弯半径和折弯角度，中性层折弯半径为R10，折弯角度为140.99°；
(2)减小折弯处支撑柱之间的中心距，同时增加折弯处支撑柱的数量，比如折弯段支撑柱之间的中心距是非折弯段的50-60％；
(3)增加均热板壳板厚度，比如壳板的厚度增加10％-50％，保证壳板折弯过程中保持不破裂。
本发明的有益效果为：
1、本发明能够显著改善悬伸处绕组的散热情况，降低电机绕组温度，提升电机额定使用功率，实现电机轻量化和微型化。
1、本发明使用已产业化生产，成本低廉。
3、本发明的制备过程操作简便，方便实用。
4、本发明结构简单，对装配要求不高。
5、本发明生产中对所涉及的装置和零件对精度要求不高，易于加工。
附图说明
图1为超薄均热板的折弯示意图；
图2为折弯后超薄均热板的展示图；
图3为超薄均热板在电机中的安装示意图。
具体实施方式
为让本领域的技术人员更加清晰直观的了解本发明，下面将结合附图，对本发明作进一步的说明。
实施例1
一种折弯异型超薄均热板的制造工艺，包括如下步骤：
1、采用超声波清洗机将生产均热板的上、下壳板浸没在无水乙醇中清洗1-5min，再使用吹风机/烤箱/自然风干等方式对其进行干燥处理。
2、制备吸液芯材料：采用激光打标机对烧结好的金属丝网定型，并使用裁切机裁剪与壳板对应数量及尺寸的金属编织带；
3、吸液芯制备：对准备好的金属丝网与金属编织带进行化学腐蚀处理，处理过后的金属丝网与金属编织带将具有良好的毛细性能。金属丝网与金属编织带的材料选用市场上超薄均热板的常用材料；化学腐蚀用到的药液为市面上用到的腐蚀药液，其以能在金属丝网与金属编织带上形成具有毛细性能的微结构。常用的金属丝网和金属编织带主要为铜金属。
4、将处理好的金属丝网和金属编织带铺放于均热板的壳板上，使用650℃的还原气体对其进行烧结处理，烧结过后的金属丝网与金属编织带应与壳板焊接为一体。还原气体具体是氮氢混合气，95％氮气+5％氢气。
5、采用冲压机对烧结好金属丝网及编织带的壳板冲注液口，接着采用点胶机对壳板自动涂上熔点630℃的高温焊膏。
6、将上壳板与下壳板组装合并后放置于清洁干净的石墨模具中固定，为了保证焊接的成功率，需要在石墨模具的顶部加1-20kg不等的配重(一般为铁块)，配重由壳板厚度、点胶量等因素决定。
7、再次使用650℃的还原气体对组装好的均热板进行高温烧结，烧结完成后将灌液管插入步骤5中冲压形成的注液口中，并采用高频感应焊机进行 焊接。
8、焊接完成后，采用真空抽注泵对超薄均热板进行验漏，若压力低于1Pa则视为验漏通过。
9、采用注射器对验漏通过后的超薄均热板进行灌液处理，灌液完成后将其放置于低于-8℃的乙醇中进行工质冻结，冻结时间大于5min。
10、再次采用真空抽注泵对内部工质冻结完成的超薄均热板进行抽真空处理，直至小于3Pa。
11、采用加热平台对抽真空后的超薄均热板除掉不凝性气体，接着采用液压钳对其进行封口处理，并使用工业胶对其进行二次封口。
12、采用电阻焊机将封口后的超薄均热板的注液管作去尾处理，并置于60℃水浴进行启动性能测试。
13、采用折弯用凹凸模具或弯管机对测试通过的超薄均热板进行折弯处理，并对折弯后的超薄均热板进行二次启动性能测试，以检验其折弯后是否失效。
如图1所示，超薄均热板折弯段中性层折弯半径为R10，折弯角度为140.99°；
本实施例中，两相邻的支撑柱的中心距为支撑柱半径的250％-400％。作为优选的实施例，支撑柱半径为0.5毫米，中心距设置在2毫米。
本实施例中的壳体厚度优选为0.2-2mm。
通过生产统计，采用上述制造工艺制备得到的超薄均热板在折弯后有效率可以达到90％以上，极大的节省了成本，同时应用于电机中可以极大的提高电机绕组的散热效率。
实施例2
通过实施例1的制造工艺制得的超薄均热板如图2所示，应用在液冷或风冷电机中作为电机定子绕组与冷却机壳之间的相变热控器件，如图3所示。应用中，超薄均热板折弯后呈波浪状，上波顶贴紧冷却机壳，下波底与电机定子的悬伸处绕组接触，从而为电机绕组提供额外的散热途径。图3展示的 是超薄均热板在电机中的安装位置，因此电机冷却机壳未画出。
以上仅为本发明的较佳实施例而已，并不用以限制本发明，凡在本发明的精神和原则之内，所作的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。

Claims (10)

  1. 一种折弯异型超薄均热板的制造工艺，其特征在于，包括如下步骤：
    清洗生产均热板的上、下壳板，然后干燥；
    准备吸液芯材料：采用激光打标机对烧结好的金属丝网定型，和/或裁剪与壳板对应数量及尺寸的金属编织带；
    吸液芯制备：对金属丝网、金属编织带进行化学腐蚀处理，处理过后的金属丝网与金属编织带将具有良好的毛细性能；
    将处理好的金属丝网、金属编织带铺放于均热板的壳板上进行烧结处理，烧结过后的金属丝网、金属编织带应与壳板连接为一体；
    对烧结好金属丝网、编织带的壳板冲注液口，接着对壳板自动涂上高温焊膏；
    将上壳板与下壳板组装合并后放置于清洁干净的石墨模具中固定；
    对组装好的均热板进行高温烧结，烧结完成后将灌液管插入注液口中并进行焊接；
    焊接完成后对超薄均热板进行灌液处理，灌液完成后将其放置于低于-8℃的乙醇中进行工质冻结；
    内部工质冻结完成的超薄均热板进行抽真空处理；
    通过加热平台对抽真空后的超薄均热板进行不凝性气体去除处理，接着进行封口处理；
    将封口后的超薄均热板的注液管作去尾处理；
    采用折弯用凹凸模具或弯管机对测试通过的超薄均热板进行折弯处理。
  2. 如权利要求1所述的一种折弯异型超薄均热板的制造工艺，其特征在于，超薄均热板的折弯段中性层折弯半径为R10，折弯角度为140.99°。
  3. 如权利要求1所述的一种折弯异型超薄均热板的制造工艺，其特征在于，超薄均热板的折弯段支撑柱之间的中心距是非折弯段的50-60％。
  4. 如权利要求1所述的一种折弯异型超薄均热板的制造工艺，其特征在于，壳板的厚度增加10％-50％。
  5. 如权利要求1所述的一种折弯异型超薄均热板的制造工艺，其特征在于，烧结处理是采用650℃的还原气体进行烧结，还原气体是95％氮气+5％氢气的混合气体。
  6. 如权利要求1所述的一种折弯异型超薄均热板的制造工艺，其特征在于，对焊接完成的超薄均热板采用真空抽注泵对超薄均热板进行验漏，若压力低于1Pa则视为验漏通过。
  7. 如权利要求1所述的一种折弯异型超薄均热板的制造工艺，其特征在于，注液管尾处理后，超薄均热板置于60℃水浴进行启动性能测试。
  8. 如权利要求7所述的一种折弯异型超薄均热板的制造工艺，其特征在于，对折弯后的超薄均热板进行二次启动性能测试，以检验其折弯后是否失效。
  9. 如权利要求1-8任一项所述的一种折弯异型超薄均热板的制造工艺制备得到的超薄均热板。
  10. 如权利要求1-8任一项所述的一种折弯异型超薄均热板的制造工艺制备得到的超薄均热板在液冷或风冷电机中作为电机定子绕组与冷却机壳之间的相变热控器件的应用。
PCT/CN2023/090429 2022-10-14 2023-04-24 一种折弯异型超薄均热板及其制造工艺和应用 WO2024077925A1 (zh)

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