Abstract:
A method of manufacturing a vapor chamber includes steps of: attaching a first edge of a first metal cover plate to a second edge of a second metal cover plate; placing the first metal cover plate and the second metal cover plate on a die after attachment; and using a punch head to punch the first edge and the second edge in a direction toward the die so as to seal the first edge and the second edge.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    1. Field of the Invention 
         [0002]    The invention relates to a vapor chamber and a method of manufacturing the same and, more particularly, to a method for sealing edges of two metal cover plates of a vapor chamber by a punch process. 
         [0003]    2. Description of the Prior Art 
         [0004]    In a vapor chamber, a working fluid is filled in a sealed chamber. The working fluid can be evaporated and condensed in cycles such that heat can be conducted by the vapor chamber uniformly and rapidly. In general, the vapor chamber essentially consists of metal casing, capillary structure and working fluid and is manufactured by an annealing process, a vacuumizing process, a soldering and sealing process, and so on. However, compared with a heat pipe, the conventional vapor chamber is more expensive due to high manufacture cost resulted from the soldering and sealing process. Therefore, how to reduce the manufacture cost resulted from the soldering and sealing process becomes a significant issue while designing the vapor chamber. 
       SUMMARY OF THE INVENTION 
       [0005]    The invention provides a vapor chamber and a method for sealing edges of two metal cover plates of the vapor chamber by a punch process, so as to solve the aforesaid problems. 
         [0006]    According to an embodiment of the invention, a method of manufacturing a vapor chamber comprises steps of attaching a first edge of a first metal cover plate to a second edge of a second metal cover plate; placing the first metal cover plate and the second metal cover plate on a die after attachment; and using a punch head to punch the first edge and the second edge in a direction toward the die so as to seal the first edge and the second edge. 
         [0007]    According to another embodiment of the invention, a vapor chamber comprises a first metal cover plate, a second metal cover plate, a capillary structure and a working fluid. A first edge of the first metal cover plate and a second edge of the second metal cover plate are sealed by the aforesaid method through a punch process. The capillary structure is formed between the first metal cover plate and the second metal cover plate. The working fluid is filled in between the first metal cover plate and the second metal cover plate. 
         [0008]    As mentioned in the above, the invention uses the punch process to seal the edges of two metal cover plates of the vapor chamber. The process of the invention is simple and the efficiency of manufacturing the vapor chamber can be improved effectively so that the manufacture cost can be reduced. 
         [0009]    These and other objectives of the present invention will no doubt become obvious to those of ordinary skill in the art after reading the following detailed description of the preferred embodiment that is illustrated in the various figures and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is a flowchart illustrating a method of manufacturing a vapor chamber according to a first embodiment of the invention. 
           [0011]      FIG. 2  is a cross-sectional view illustrating a vapor chamber before a punch process. 
           [0012]      FIG. 3  is a cross-sectional view illustrating the vapor chamber after the punch process. 
           [0013]      FIG. 4  is a microscopic diagram illustrating the first edge and the second edge of the vapor chamber after the punch process. 
           [0014]      FIG. 5  is a cross-sectional view illustrating a vapor chamber after the punch process according to a second embodiment of the invention. 
           [0015]      FIG. 6  is a cross-sectional view illustrating a vapor chamber before the punch process according to a third embodiment of the invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    Referring to  FIGS. 1 to 4 ,  FIG. 1  is a flowchart illustrating a method of manufacturing a vapor chamber according to a first embodiment of the invention,  FIG. 2  is a cross-sectional view illustrating a vapor chamber  1  before a punch process,  FIG. 3  is a cross-sectional view illustrating the vapor chamber  1  after the punch process, and  FIG. 4  is a microscopic diagram illustrating the first edge  100  and the second edge  120  of the vapor chamber  1  after the punch process. 
         [0017]    First of all, step S 10  is performed to form a capillary structure  14  between a first metal cover plate  10  and a second metal cover plate  12 , wherein the capillary structure  14  may be a groove-type capillary structure, a porous capillary structure, a mesh capillary structure, a sintered capillary structure or a compound capillary structure according to practical applications. It should be noted that the aforesaid compound capillary structure may consist of at least two capillary structures selected from the groove-type capillary structure, the porous capillary structure, the mesh capillary structure and the sintered capillary structure. Afterward, step S 12  is performed to attach a first edge  100  of the first metal cover plate  10  to a second edge  120  of the second metal cover plate  12  and dispose a plurality of support members  16  between the first metal cover plate  10  and the second metal cover plate  12  so as to support the first metal cover plate  10  and the second metal cover plate  12 . Accordingly, the support members  16  can prevent the first metal cover plate  10  and the second metal cover plate  12  from caving in or bulging out. 
         [0018]    Step S 14  is then performed to place the first metal cover plate  10  and the second metal cover plate  12  on a die  30  after attachment. Step S 16  is then performed to use a punch head  32  to punch the first edge  100  and the second edge  120  in a direction toward the die  30  (as the direction indicated by an arrow A of  FIG. 3 ) so as to seal the first edge  100  and the second edge  120 . In this embodiment, the first metal cover plate  10  and the second metal cover plate  12  may be made of, but not limited to, copper, aluminum or other metal with low hardness. After punching the first edge  100  and the second edge  120  by an appropriate force, the metal grain boundaries of the first edge  100  and the second edge  120  will crack and then recombine so that the first edge  100  and the second edge  120  are sealed together, as shown in  FIG. 4 . Accordingly, the invention can seal the periphery of the vapor chamber  1  rapidly and effectively by the punch process, so as to reduce the manufacture cost. It should be noted that since the first edge  100  and the second edge  120  are sealed by the punch process, there is no any solder, glue or other additional materials remained between the first edge  100  and the second edge  120  and there is no soldering mark formed between the first edge  100  and the second edge  120 , as shown in  FIG. 4 . 
         [0019]    Step S 18  is then performed to fill a working fluid  18  (e.g. water) in between the first metal cover plate  10  and the second metal cover plate  12 . Finally, step S 20  is performed to vacuumize the chamber between the first metal cover plate  10  and the second metal cover plate  12  so as to complete the vapor chamber  1  shown in  FIG. 3 . 
         [0020]    As shown in  FIG. 3 , the vapor chamber  1 , which is manufactured by the aforesaid steps, comprises the aforesaid first metal cover plate  10 , second metal cover plate  12 , capillary structure  14 , support members  16  and working fluid  18 . In this embodiment, the punch head  32  may cut a material  34  form an end of the first edge  100  and the second edge  120  while it punches the first edge  100  and the second edge  120 , so as to flat and smooth the sealed outer surface of the first edge  100  and the second edge  120 . 
         [0021]    Referring to  FIG. 5  along with  FIG. 3 ,  FIG. 5  is a cross-sectional view illustrating a vapor chamber  1 ′ after the punch process according to a second embodiment of the invention. The differences between the vapor chamber  1 ′ and the aforesaid vapor chamber  1  are that the vapor chamber  1 ′ further comprises a fastener  20  for clamping the first edge  100  and the second edge  120 , which have been sealed, so as to enhance sealing effect. It should be noted that the same elements in  FIG. 5  and  FIG. 3  are represented by the same numerals, so the repeated explanation will not be depicted herein again. 
         [0022]    Referring to  FIG. 6  along with  FIG. 2 ,  FIG. 6  is a cross-sectional view illustrating a vapor chamber  1 ″ before the punch process according to a third embodiment of the invention. The differences between the vapor chamber  1 ″ and the aforesaid vapor chamber  1  are that the first edge  100  and the second edge  120  of the vapor chamber  1 ″ have rough surface structures  102  and  122 , respectively, before being punched. When the first edge  100  and the second edge  120  of the vapor chamber  1 ″ are punched by the die  30  and the punch head  32  of  FIG. 3 , the metal grain boundaries of the first edge  100  and the second edge  120  will be destroyed by the rough surface structures  102  and  122  much more easily, so as to enhance sealing effect. In this embodiment, the rough surface structures  102  and  122  maybe, but not limited to, saw-toothed shapes. Furthermore, the invention may form the rough surface structure  102  on the first edge  100  only or form the rough surface structure  122  on the second edge  120  only. In other words, at least one of the first edge  100  and the second edge  120  may have a rough surface structure before being punched according to practical applications. It should be noted that the same elements in  FIG. 6  and  FIG. 2  are represented by the same numerals, so the repeated explanation will not be depicted herein again. 
         [0023]    As mentioned in the above, the invention uses the punch process to seal the edges of two metal cover plates of the vapor chamber. The process of the invention is simple and the efficiency of manufacturing the vapor chamber can be improved effectively so that the manufacture cost can be reduced. Furthermore, the invention may use the fastener to clamp the edges of the two metal cover plates, which have been sealed, so as to enhance sealing effect. 
         [0024]    Those skilled in the art will readily observe that numerous modifications and alterations of the device and method may be made while retaining the teachings of the invention. Accordingly, the above disclosure should be construed as limited only by the metes and bounds of the appended claims.