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

“电力电子、机器和驱动（PEMD）是能够控制和输送电能的技术，包括运输、能源生产和分配、工业机器和机器人技术中的推进。它们用于供应链，如导体和半导体，转换器/逆变器系统，[和]新型电动机拓扑结构。“（KTN，InnovateUK）PEMD的高效和有效的热管理正在发展。优化热管理产品以匹配更高的功率密度，同时降低重量和占地面积，这迫切需要在散热器和冷却板技术方面进行创新。电动汽车（EV）电池和大功率电子设备的功率密度不断提高，导致发热速度超过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体温一样，这些高性能产品的下一步热管理也是循环冷却液。然而，与生物学上生长相互连接的血管网络的生物体相反，在部件内部制造类似的通道是一个重大的工程挑战。PSL Assemblies Ltd（PSL）运营的当前解决方案需要结合多种材料和许多劳动密集型步骤。TWI公司最近发明了一种新的亚表面加工技术，称为CoreFlow（TM）。它穿过零件的外“皮”，去除零件的内“芯”，所有这些都不需要去除外皮。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，从而实现更小的形状因子和更轻的热管理组件。此外，它是数字驱动的，允许创建定制的子表面网络尺寸和图案，而不需要额外的工具。这种方法具有变革性潜力，可以生产具有更高可靠性的更高性能热管理解决方案。**_这种方法的主要缺点是它依赖于昂贵的专业制造设备。混合制造技术有限公司（HMT）将专业工艺模块化为可用于主流机床（制造业中最基础的金属加工工具）的头部。在_SubSurface_项目中，HMT将把TWI发明的CoreFlow（TM）工艺迁移到一个高度可访问和具有成本效益的解决方案中，可以改造现有的CNC机床。这将允许在一台机器上完成表面下网络的形成和外部加工，并将竞争力和性能提升到新的高度。这将使_PSL_和相关的英国行业在热管理解决方案方面取得前所未有的领导地位，以实现下一代PEMD技术和定制的液体冷却产品。

"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.