Patent Publication Number: US-2011048341-A1

Title: Vapor chamber and method for manufacturing the same

Description:
BACKGROUND 
     1. Technical Field 
     The present disclosure relates to vapor chambers and, more particularly, to a vapor chamber having stable and reliable performance and a method for manufacturing such vapor chamber. 
     2. Description of Related Art 
     Generally, vapor chambers are used to dissipate and transfer heat generated by electronic components. The vapor chamber includes a plate-shaped container, a wick structure formed on inner surfaces of the container, and working fluid sealed inside the container. The container is prone to be deformed when it is pressed or when the working fluid is vaporized, thereby adversely affecting the stable performance of the vapor chamber. 
     What is needed, therefore, is a vapor chamber which can overcome the limitations described, and a method for manufacturing such a vapor chamber. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is an isometric, assembled view of a vapor chamber in accordance with a first embodiment of the present disclosure, the vapor chamber including a container. 
         FIG. 2  is an isometric view of a metal tube for manufacturing the container of the vapor chamber of  FIG. 1 . 
         FIG. 3  is an isometric view of the metal tube of  FIG. 2  having been flattened into the container, with a wick structure arranged on inner surfaces of the metal tube. 
         FIG. 4  is an isometric view of a supporting structure of the vapor chamber of  FIG. 1 . 
         FIG. 5  is an isometric view similar to  FIG. 1 , but with a part of the container cut away. 
         FIG. 6  is an isometric view of a supporting structure of a vapor chamber of a second embodiment of the present disclosure. 
         FIG. 7  is a side view of the supporting structure of  FIG. 6 . 
         FIG. 8  is an isometric view of a supporting structure of a vapor chamber of a third embodiment of the present disclosure. 
         FIG. 9  is an isometric view of a supporting structure of a vapor chamber of a fourth embodiment of the present disclosure. 
         FIG. 10  is a side view of the supporting structure of  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring to  FIGS. 1-5 , a vapor chamber in accordance with a first embodiment of the present disclosure comprises a container  11 , a continuous wick structure  13  mounted on inner surfaces of the container  11 , a supporting structure  15  received in the container  11  and abutting opposite sidewalls of the container  11 , and working fluid (not shown) contained in the container  11 . The container  11  is a plate-type structure, and is formed by flattening a metal tube  10 . The wick structure  13  is a sintered wick layer formed from sintering metal powder. 
     The supporting structure  15  is formed from a flat metal sheet by punching. The supporting structure  15  comprises a number of first supporting members  151 , a number of elongate second supporting members  153 , a number of first connecting members  155 , and a number of second connecting members  156 . 
     The first supporting members  151  are arranged in a plurality of spaced rows, each row extending along a widthwise direction of the supporting structure  15 . Each row of the first supporting members  151  comprises a plurality of inverted U-shaped first supporting portions  152  and two inverted U-shaped second supporting portions  154 . The first and second supporting portions  152 ,  154  are aligned with each other and spaced from each other. The first supporting portions  152  of each row of the first supporting members  151  are arranged between the two second supporting portions  154  of that row. That is, the two second supporting portions  154  are located at front and rear ends of the row of first supporting members  151 . Each first supporting portion  152  comprises a top plate  1521 , and a first sidewall  1523  and a second sidewall  1525  extending downwardly from opposite edges of the top plate  1521 . A central portion of the top plate  1521  defines a first through hole  1524  therein. A first through channel  1516  is defined and enclosed by the first and second sidewalls  1523 ,  1525  of all of the first supporting portions  152  in the one row, and is thereby defined as spanning between front and rear ends of the row of first supporting portions  152 . 
     Each second supporting portion  154  comprises a top plate  1541 , and a first sidewall  1543  and a second sidewall  1545  extending downwardly from opposite edges of the top plate  1541 . A second through channel  1517  is defined and enclosed by the first and second sidewalls  1543 ,  1545 , and is thereby defined as spanning between front and rear ends of the second supporting portion  154 . The first and second through channels  1516 ,  1517  of a corresponding row of the first supporting members  151  face each other end-to-end and communicate with each other. Vaporized working fluid spreads outwardly from the first and second through channels  1516 ,  1517  and upwardly from the first through holes  1524  and gaps between the first and second supporting portions  152 ,  154 . Top surfaces of the top plates  1521  of the first supporting portions  152  and top surfaces of the top plates  1541  of the second supporting portions  154  are coplanar and abut against the wick structure  13  mounted on a top end of the container  11 . 
     Each of the second supporting members  153  is arranged along the widthwise direction of the supporting structure  15 . Each second supporting member  153  is integrally positioned between two adjoining rows of the first supporting members  151 . Each second supporting member  153  comprises an elongated supporting plate  1531 , and a plurality of pairs of spaced sidewalls  1533  extending perpendicularly and downwardly from opposite edges of the supporting plate  1531 . The pairs of sidewalls  1533  are arranged along a lengthwise direction of the supporting plate  1531 . All the sidewalls  1533  along one lateral side (the left side, as viewed in  FIG. 4 ) of the supporting plate  1531  are aligned with the second sidewalls  1525 ,  1545  of the first and second supporting portions  152 ,  154  in the adjacent row of first and second supporting portions  152 ,  154 . All the sidewalls  1533  along an opposite lateral side (the right side, as viewed in  FIG. 4 ) of the supporting plate  1531  are aligned with the first sidewalls  1523 ,  1543  of the first and second supporting portions  152 ,  154  in the adjacent row of first and second supporting portions  152 ,  154 . A central portion of the supporting plate  1531  defines a number of second through holes  1534  therein to allow the vaporized working fluid to flow therethrough. A top surface of the supporting plate  1531  and the top surfaces of the top plates  1521  of the first supporting portions  152  of the two adjacent rows of first supporting members  151  are coplanar with one another. 
     The first connecting members  155  are rectangular sheets. The first connecting members  155  are arranged in a plurality of rows, each row extending along the widthwise direction of the supporting structure  15 . Each row of the first connecting members  155  is integrally positioned between an adjacent row of the first supporting members  151  and an adjacent second supporting member  153 . The first connecting members  155  of each row of the first connecting members  155  are spaced from each other. 
     First edges of the row of first connecting members  155  at one side of each second supporting member  153  perpendicularly connect with bottom ends of the sidewalls  1533  of the second supporting member  153 . Opposite second edges of such row of the first connecting members  155  perpendicularly connect with bottom ends of the first sidewalls  1523 ,  1543  of the first and second supporting portions  152 ,  154  of the adjacent row of first supporting members  151 . First edges of the row of first connecting members  155  at an opposite side of said each second supporting member  153  perpendicularly connect with bottom ends of the sidewalls  1533  of the second supporting member  153 . Opposite second edges of such row of the first connecting members  155  perpendicularly connect with bottom ends of the second sidewalls  1525 ,  1545  of the first and second supporting portions  152 ,  154  of the adjacent row of first supporting members  151 . 
     Bottom surfaces of the first connecting members  155 , the bottom ends of the first and second sidewalls  1523 ,  1525 ,  1543 ,  1545  of the first and second supporting portions  152 ,  154 , and the bottom ends of the sidewalls  1533  of the second supporting member  153  are all coplanar with one another, and abut against the wick structure  13  mounted on a bottom end of the container  11 . In each row of the first connecting members  155 , all but two of the first connecting members  155  has a third through hole  1551  defined therein, to allow the vaporized working fluid to flow therethrough. Only the two endmost first connecting members  155  in each row of the first connecting members  155  do not have a third through hole  1551  defined therein. In the illustrated embodiment, one of such two endmost first connecting members  155  has a cutout (not labeled) defined therein, the cutout being equivalent to part of a third through hole  1551 . 
     One second supporting member  153 , two corresponding adjacent rows of first supporting members  151  and two corresponding adjacent rows of first connecting members  155  connecting the second and first supporting members  153 ,  151 , cooperatively form a supporting section (not labeled). Each of the second connecting members  156  is an elongated sheet, and is integrally located between two adjoining rows of the first supporting members  151  of two adjoining supporting sections. Each second connecting member  156  perpendicularly connects with the bottom ends of the first and second sidewalls  1523 ,  1525 ,  1543 ,  1545  of the first and second supporting portions  152 ,  154  of the adjacent rows of first supporting members  151 . Bottom surfaces of the second connecting members  156  and the bottom surfaces of the first connecting members  155  are all coplanar with one another. A plurality of fourth through holes  1561  is defined in most portions of each second connecting member  156 , except two end portions thereof. In the illustrated embodiment, one of such two end portions has a cutout (not labeled) defined therein, the cutout being equivalent to part of a fourth through hole  1561 . 
     The supporting structure  15  further comprises two elongated mounting plates  157  extending outwardly from lateral ends thereof. In the illustrated embodiment, a left-hand one of the mounting plates  157  perpendicularly connects with an adjacent row of modified first supporting members  151 . The modified first supporting members  151  do not have first sidewalls  1523 ,  1543 . Instead, a continuous plate runs along the lengthwise direction of the row of modified first supporting members  151 , the continuous plate occupying a position that would otherwise be occupied by first sidewalls  1523 ,  1543 . The left-hand mounting plate  157  perpendicularly connects with a bottom end of such continuous plate. A right-hand one of the mounting plates  157  perpendicularly connects with bottom ends of an adjacent row of the first supporting members  151 . In particular, the right-hand mounting plate  157  perpendicularly connects with the bottom ends of the second sidewalls  1525 ,  1545  of the adjacent row of first supporting members  151 . Bottom surfaces of both the mounting plates  157  are coplanar with the bottom surfaces of the first connecting members  155 . 
     When a bottom end of the vapor chamber thermally contacts one or more electronic components (not shown), the working fluid absorbs heat and is vaporized. The vaporized working fluid spreads outwardly from the first and second through channels  1516 ,  1517 ; and spreads upwardly from the first, second, third and fourth through holes  1524 ,  1534 ,  1551 ,  1561 , from the gaps between the first and second supporting portions  152 ,  154 , and from gaps between the first connecting members  155  of the supporting structure  15 . When the vaporized working fluid arrives at a top end of the vapor chamber, heat of the vaporized working fluid is absorbed by the top end of the container  11 . Thus, the working fluid is condensed and flows back to the bottom end of the vapor chamber via the wick structure  13 . 
     Referring to  FIGS. 6-7 , these illustrate a supporting structure  16  of a vapor chamber of a second embodiment of the present disclosure. The supporting structure  16  is generally in the form of a rectangular metal sheet, and comprises a number of first supporting members  161  and second supporting members  163 . The first supporting members  161  protrude upwardly and are located at a top side of the supporting structure  16 . The second supporting members  163  protrude downwardly and are located at a bottom side of the supporting structure  16 . Each of the first supporting members  161  has an inverted U-shaped configuration, and each of the second supporting members  163  has a U-shaped configuration. 
     The first and second supporting members  161 ,  163  are arranged in a number of rows along a widthwise direction of the supporting structure  16 , respectively. The rows of first supporting members  161  and the rows of second supporting members  163  are alternately arranged side by side. Left bottom ends of the first supporting members  161  of one row connect with right top ends of the second supporting members  163  of a corresponding adjacent row. Right bottom ends of the first supporting members  161  of one row connect with left top ends of the second supporting members  163  of a corresponding adjacent row. Each pair of first and second supporting members  161 ,  163  connected to each other forms an S-shaped supporting section (not labeled). The supporting sections are arranged in a plurality of rows along the widthwise direction of the supporting structure  16 . A rectangular opening  165  is defined between each two adjacent supporting sections in each row of the supporting sections. Each two adjacent rows of the supporting sections are spaced from each other by a beam (not labeled). Each of the first and second supporting members  161 ,  163  defines a through hole  164  at a central portion thereof, to allow vaporized working fluid to flow therethrough. 
     Considered another way, the first and second supporting members  161 ,  163  are alternately interconnected with each other in lines, each line running along a lengthwise direction of the supporting structure  16 . The lines of first and second supporting members  161 ,  163  are spaced apart from each other, by reason of the provision of the rectangular openings  165 . In particular, each of lines of rectangular openings  165  essentially separates two adjacent lines of first and second supporting members  161 ,  163 . 
     Referring to  FIG. 8 , this illustrates a supporting structure  17  of a vapor chamber of a third embodiment of the present disclosure. The supporting structure  17  is generally in the form of a rectangular metal sheet, and comprises a number of supporting members  171 . Each of the supporting members  171  is generally in the form of a hollow truncated pyramid. Considered another way, each supporting member  171  has a generally frusto-conical shape. In particular, each supporting member  171  has a square base, and a flat, round top. The supporting members  171  extend upwardly from a top surface of the supporting structure  17  and are arranged in a plurality of rows along a lengthwise direction of the supporting structure  17 . An opening  173  is defined between two adjoining supporting members  171  along the lengthwise direction of the supporting structure  17  and along a widthwise direction of the supporting structure  17 . That is, the supporting members  171  and openings  173  are arranged across the supporting structure  17  like a checkerboard. A through hole  175  is defined at a central portion of each supporting member  171 , to allow vaporized working fluid to flowing therethrough. 
     Referring to  FIGS. 9-10 , these illustrate a supporting structure  18  of a vapor chamber of a fourth embodiment of the present disclosure. The supporting structure  18  is generally in the form of a rectangular metal sheet, and comprises a number of first supporting members  181  and a number of second supporting members  183 . The first and second supporting members  181 ,  183  are generally in the form of hollow tapered dome-shaped protrusions. The first supporting members  181  extend upwardly and are located at a top side of the supporting structure  18 . The second supporting members  183  extend downwardly and are located at a bottom side of the supporting structure  18 . The first supporting members  181  are arranged in a number of rows along a widthwise direction of the supporting structure  18 , and the second supporting members  183  are also arranged in a number of rows along the widthwise direction of the supporting structure  18 . The rows of first supporting members  181  and the rows of second supporting members  183  are alternately arranged side by side. 
     In each row of first supporting members  181 , a through hole  185  is defined between each two adjacent first supporting members  181 . In each row of second supporting members  183 , a through hole  185  is defined between each two adjacent second supporting members  183 . One through hole  185  is located between each two adjacent first supporting members  181  along a lengthwise direction of the supporting structure  18 . One through hole  185  is located between each two adjacent second supporting members  183  along the lengthwise direction of the supporting structure  18 . Thus, the first supporting members  181 , the second supporting members  183  and the through holes  185  are arranged like a checkerboard across the supporting structure  18 . In particular, the first supporting members  181  together with the second supporting members  183  can be considered to occupy positions corresponding to one color of a checkerboard, and the through holes  185  can be considered to occupy positions corresponding to the other color of a checkerboard. Each of the first and second supporting members  181 ,  183  defines a through hole  187  at a central portion thereof. 
     An exemplary method for manufacturing a vapor chamber includes steps as follows: 
     Firstly, as shown in  FIG. 2 , a metal tube  10  is provided. The metal tube  10  has a predetermined length, and is made of a material with good thermal conductivity such as copper. 
     Secondly, as shown in  FIG. 3 , the metal tube  10  is flattened into a rectangular plate-shape container  11 , and thus has two elongated openings at two opposite ends thereof. 
     Thirdly, an insert (not shown) is provided and inserted into the container  11 . The insert has a configuration similar to that of the container  11 , but has a slightly smaller size than the container  11 . Metal powder is filled between the inner surfaces of the container  11  and an outer surface of the insert. Then the metal powder is sintered on the inner surfaces of the container  11  by heat treating the container  11 , to form the wick structure  13  over the inner surfaces of the container  11 . 
     Fourthly, a supporting member such as one of the supporting members  15 ,  16 ,  17 ,  18  is provided and inserted into the container  11 . The two opposite outer flat surfaces of the container  11  are pressed to make the top and bottom surfaces of the supporting member  15 ,  16 ,  17 , or  18  engage with the wick structure  13  formed on the inner surfaces of the container  11 . 
     Finally, the openings of the container  11  are sealed, the container  11  is evacuated, and working fluid is filled in the container  11 . 
     It is to be understood, however, that even though numerous characteristics and advantages of various embodiments have been set forth in the foregoing description, together with details of the structures and functions of the embodiments, the disclosure is illustrative only, and changes may be made in detail, especially in matters of shape, size, and arrangement of parts within the principles of the disclosure to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.