SubSurface – Rapid Scale-up of Custom Cooling Solutions Through an Innovative Sub-surface Channelling Technique

SubSurface — 通过创新的地下通道技术快速扩大定制冷却解决方案

• 批准号: 10023786
• 金额: $ 50.3万
• 依托单位: HYBRID MANUFACTURING TECHNOLOGIES LIMITED
• 依托单位国家: 英国
• 项目类别: Collaborative R&D
• 财政年份: 2022
• 资助国家: 英国
• 起止时间: 2022 至 无数据
• 项目状态: 已结题
• 来源: https://gtr.ukri.org/projects?ref=10023786
• 关键词: SubSurface; Rapid; Scale; up; Custom

"Power Electronics, Machines and Drives (PEMD) are technologies that enable the control and delivery of electrical energy and includes propulsion in transportation, energy generation and distribution, industrial machines and robotics. They are used in supply chains, like conductors and semiconductors, converter/inverter systems, \[and\] novel electric motor topologies." (KTN, InnovateUK)Efficient and effective thermal management of PEMD is evolving. Optimisation of thermal management products to match ever-higher power densities, whilst reducing weight and footprint, has created an urgent need for innovation in heatsink and cooling plate technology.The increased power densities of electric vehicle (EV) batteries and high-power electronics have led to heat generation at rates beyond the ability to simply air-cool them. Just as many living organisms regulate their temperature by circulating blood throughout their bodies, the next step for thermal management in these high-performance products is to also circulate a cooling liquid. However, contrary to living organisms that biologically grow an interconnected network of blood vessels, manufacturing similar passages inside of parts is a significant engineering challenge. Current solutions, as operated by _PSL Assemblies Ltd_ (PSL), require combining multiple materials and many labour-intensive steps._TWI Ltd_ (TWI) has recently invented a new sub-surface machining technique called CoreFlow(TM). It reaches through the outer "skin" of a part to remove the inside "core" of it, all without removing the outer skin. This new solid-state process allows for the creation of sub-surface networks of channels to be created within solid metal parts directly, thus enabling smaller form-factor and lighter thermal management components. Furthermore, it is digitally driven allowing for the creation of customised sub-surface network sizes and patterns without the need for additional tooling. This approach has transformative potential for producing higher-performance thermal management solutions with elevated reliability.**_The main drawback of this approach is that it relies on costly specialised manufacturing equipment._**_Hybrid Manufacturing Technologies Ltd_ (HMT) modularises specialist processes into heads that are useable on mainstream machine tools (the most foundational metalworking tool in the manufacturing industry). In the _SubSurface_ project HMT will migrate the CoreFlow(TM) process invented by TWI into a highly accessible and cost-effective solution, retrofittable to existing CNC machines. This will allow the formation of sub-surface networks and external machining to be accomplished in one machine and drive competitiveness and performance to new heights. This will empower _PSL_ and associated UK industry unprecedented leadership in thermal management solutions to enable next-generation PEMD technologies and bespoke liquid-cooled products.

“电力电子、机器和驱动器 (PEMD) 是能够控制和输送电能的技术，包括运输、能源生成和分配、工业机器和机器人领域的推进。它们用于供应链，如导体和半导体、转换器/逆变器系统，\[和\]新颖的电动机拓扑。” （KTN，InnovateUK）高效且有效的 PEMD 热管理正在不断发展。优化热管理产品以适应更高的功率密度，同时减轻重量和占地面积，迫切需要散热器和冷却板技术的创新。电动汽车 (EV) 电池和高功率电子设备功率密度的增加已经导致热量产生的速度超出了简单空气冷却的能力。正如许多生物体通过在体内循环血液来调节温度一样，这些高性能产品中热管理的下一步也是循环冷却液体。然而，与生物体生长相互连接的血管网络相反，在零件内部制造类似的通道是一项重大的工程挑战。当前由_PSL Assemblies Ltd_ (PSL) 运营的解决方案需要结合多种材料和许多劳动密集型步骤。_TWI Ltd_ (TWI) 最近发明了一种名为 CoreFlow(TM) 的新型次表面加工技术。它穿过零件的外“皮”，去除其内部“芯”，而无需去除外皮。这种新的固态工艺允许直接在固体金属部件内创建通道的次表面网络，从而实现更小外形和更轻的热管理组件。此外，它是数字驱动的，允许创建定制的地下网络尺寸和模式，而无需额外的工具。这种方法具有变革潜力，可以生产更高性能和更高可靠性的热管理解决方案。**_这种方法的主要缺点是它依赖昂贵的专业制造设备。**_Hybrid Manufacturing Technologies Ltd_ (HMT) 将专业流程模块化到头部可在主流机床（制造业中最基本的金属加工工具）上使用。在_SubSurface_ 项目中，HMT 将把TWI 发明的CoreFlow(TM) 工艺迁移到一个易于访问且经济高效的解决方案中，并可改装到现有的数控机床上。这将使地下网络的形成和外部加工在一台机器上完成，并将竞争力和性能推向新的高度。这将使 _PSL_ 和英国相关行业在热管理解决方案方面获得前所未有的领导地位，从而实现下一代 PEMD 技术和定制液冷产品。