Phase change material heat sink using additive manufacturing and method

Abstract

A heat sink includes a lower shell, an upper shell, and an internal matrix having a space. The space is configured to receive a phase change material. The lower shell, the upper shell and the internal matrix are formed as a single component using additive manufacturing techniques. The upper shell can include a fill port and a vent port. The fill port can be configured to provide a path into the space of the internal matrix for the phase change material. The fill port and the vent port can each be configured to receive a seal plug, such as an expansion plug.

What is claimed is: 
     
         1 . A heat sink comprising:
 a lower shell;   an upper shell; and   an internal matrix comprising a space, wherein the space is configured to receive a phase change material;   wherein the lower shell, the upper shell, and the internal matrix are formed as a single component using additive manufacturing techniques.   
     
     
         2 . The heat sink of  claim 1 , wherein the upper shell comprises a fill port and a vent port. 
     
     
         3 . The heat sink of  claim 2 , wherein the fill port is configured to provide a path into the space of the internal matrix for the phase change material. 
     
     
         4 . The heat sink of  claim 2 , wherein the fill port and the vent port are each configured to receive a seal plug. 
     
     
         5 . The heat sink of  claim 4 , wherein each seal plug comprises an expansion plug. 
     
     
         6 . The heat sink of  claim 1 , wherein:
 the lower shell, the upper shell, and the internal matrix comprise a thermally-conductive material; and   the internal matrix is designed to optimize heat transfer into the phase change material.   
     
     
         7 . A phase change material (PCM) heat sink comprising:
 a phase change material;   a lower shell;   an upper shell; and   an internal matrix comprising a space, wherein the space is configured to receive the phase change material;   wherein the lower shell, the upper shell, and the internal matrix are formed as a single component using additive manufacturing techniques.   
     
     
         8 . The PCM heat sink of  claim 7 , wherein the upper shell comprises a fill port and a vent port. 
     
     
         9 . The PCM heat sink of  claim 8 , wherein the fill port is configured to provide a path into the space of the internal matrix for the phase change material. 
     
     
         10 . The PCM heat sink of  claim 8 , wherein the fill port and the vent port are each configured to receive a seal plug. 
     
     
         11 . The PCM heat sink of  claim 8 , further comprising:
 a first seal plug configured to seal the fill port; and   a second seal plug configured to seal the vent port.   
     
     
         12 . The PCM heat sink of  claim 11 , wherein each seal plug comprises an expansion plug. 
     
     
         13 . The PCM heat sink of  claim 7 , wherein:
 the lower shell, the upper shell, and the internal matrix comprise a thermally-conductive material; and   the internal matrix is designed to optimize heat transfer into the phase change material.   
     
     
         14 . An apparatus comprising:
 a structural component; and   a heat sink comprising a lower shell, an internal matrix configured to receive a phase change material, and an upper shell, the internal matrix comprising a plurality of parallel pins or plates;   wherein the lower shell, the internal matrix, and the upper shell of the heat sink comprise a single-structure component that is incorporated into the structural component such that the heat sink and the structural component are integral.   
     
     
         15 . The apparatus of  claim 14 , wherein:
 the upper shell comprises a fill port and a vent port; and   the fill port is configured to provide a path into the space of the internal matrix for the phase change material.   
     
     
         16 . The apparatus of  claim 15 , further comprising:
 a first seal plug configured to seal the fill port; and   a second seal plug configured to seal the vent port.   
     
     
         17 . The apparatus of  claim 16 , wherein each seal plug comprises an expansion plug. 
     
     
         18 . The apparatus of  claim 14 , wherein:
 the internal matrix comprises the plurality of parallel pins; and   the parallel pins comprise hour-glass shaped pins.   
     
     
         19 . The apparatus of  claim 14 , wherein the internal matrix comprises:
 the plurality of parallel plates; and   a second plurality of parallel plates perpendicular to the plurality of parallel plates.   
     
     
         20 . The apparatus of  claim 14 , wherein the structural component comprises an airframe or a bulkhead.