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US-20260129812-A1 - BRIDGED PIN ARRAY FOR IMPROVED STIFFNESS

US20260129812A1US 20260129812 A1US20260129812 A1US 20260129812A1US-20260129812-A1

Abstract

A heat sink includes a base extending from a first end to a second end and a plurality of pin fins extending from the base and arranged in a number of columns including a first column and a second column. Each pin fin includes a lower portion at or near the base and an opposing top portion spaced apart from the base. A plurality of bridged ribs includes a first plurality of bridged ribs, wherein the first plurality of bridged ribs each connect the top portion of one of the pin fins in the first column with the top portion of one of the pin fins in the second column.

Inventors

  • Alexander PLEDGER

Assignees

  • DENSO INTERNATIONAL AMERICA, INC.
  • DENSO CORPORATION

Dates

Publication Date
20260507
Application Date
20250324

Claims (20)

  1. 1 . A heat sink comprising: a base extending from a first end to a second end; a plurality of pin fins extending from the base and arranged in a number of columns including a first column and a second column, wherein each pin fin includes a lower portion at or near the base and an opposing top portion spaced apart from the base; and a plurality of bridged ribs including a first plurality of bridged ribs, wherein the first plurality of bridged ribs each connect the top portion of one of the pin fins in the first column with the top portion of one of the pin fins in the second column.
  2. 2 . The heat sink of claim 1 wherein the plurality of bridged ribs have a thickness of less than 10% of a height of the plurality of pin fins of the first column and the second column.
  3. 3 . The heat sink of claim 1 wherein the plurality of bridged ribs are 3D-printed bridged ribs.
  4. 4 . The heat sink of claim 1 wherein the plurality of bridged ribs are provided in less than 10% of the number of columns of the plurality of pin fins.
  5. 5 . The heat sink of claim 1 wherein the first plurality of bridged ribs only connect some of the top portions of some of the pin fins in the first column and the second column.
  6. 6 . The heat sink of claim 1 wherein the plurality of bridged ribs increase an overall stiffness of the heat sink to resists bending and torsional moments.
  7. 7 . The heat sink of claim 1 wherein the base extends from a first side and a second side opposite the first side, wherein the columns of the plurality of pin fins extend from adjacent the first side to adjacent the second side; and wherein the top portions of the pin fins in the first column are connected to the top portions of the pin fins in the second column by the first plurality of bridged ribs.
  8. 8 . The heat sink of claim 1 wherein a plurality of pin fins in a third column are located between the first column and the second column in a staggered arrangement.
  9. 9 . The heat sink of claim 8 wherein a third column of the pin fins is adjacent the first end, and wherein the top portions of the pin fins in the third column are connected by a second plurality of bridges.
  10. 10 . A heat sink comprising: a base extending from a first end to a second end; a plurality of pin fins extending from the base wherein each pin fin includes a lower portion at or near the base and an opposing top portion spaced apart from the base; a plurality of bridges angled to align with a fluid flow direction from the first end to the second end for minimizing effects on a pressure drop of the heat sink; a first column of the pin fins adjacent the first end, wherein the top portions of at least two of the pin fins in the first column are connected by a first of the plurality of bridges; and a second column of the pin fins adjacent the second end, wherein the top portions of at least two of the pin fins in the second column are connected by a second of the plurality of bridges.
  11. 11 . The heat sink of claim 10 wherein the plurality of bridges are 3D-printed bridges.
  12. 12 . The heat sink of claim 10 wherein the plurality of bridges are provided with a thickness of less than 10% of a height of the plurality of pin fins connected by the plurality of bridges.
  13. 13 . The heat sink of claim 10 wherein the base extend from a first side to a second side, wherein in the first column and the second column of pin fins extend from adjacent the first side to adjacent the second side; and wherein the top portions of the pin fins in the first column are connected by the first plurality of bridges or the second column are connected by the second plurality of bridges.
  14. 14 . The heat sink of claim 10 further comprising: a third column of the pin fins and a fourth column of pin fins spaced apart from the first end and the second end, wherein a third of the plurality of bridges each connect the top portion of one of the pin fins in the third column with the top portion of one of the pin fins in the fourth column.
  15. 15 . The heat sink of claim 14 wherein in the plurality of pin fins connected by the plurality of bridges are provided in less than 10% of a number of the plurality of pins.
  16. 16 . A method of manufacturing a heat sink, the method comprising: forming a plurality of pin fins that extend from a base of the heat sink, wherein each pin fin includes a lower portion at or near the base and an opposing top portion spaced apart from the base; forming a plurality of bridged ribs using an additive manufacturing process, wherein each of the plurality of bridged ribs connect the top portion of one of the plurality of pin fins to the top portion of another of the plurality of pin fins; and wherein the plurality of bridged ribs increase an overall stiffness of the heat sink to resists bending and torsional moments.
  17. 17 . The method of claim 16 wherein plurality of pin fins are arranged in a number of columns, and the plurality of bridged ribs each connect a pair of the plurality of pin fins in a first column and a second column.
  18. 18 . The method of claim 17 wherein the plurality of bridged ribs are provided in less than 10% of the number of columns of the plurality of pin fins.
  19. 19 . The method of claim 16 wherein the plurality of bridges are provided with a thickness of less than 10% of a height of the plurality of pin fins connected by the plurality of bridges.
  20. 20 . The method of claim 16 wherein: a plurality of pin fins adjacent a first end of the heat sink are connected by the plurality of bridges; a plurality of pin fins adjacent a second end of the heat sink are connected by the plurality of bridged ribs; wherein the plurality of bridged ribs connecting the plurality of pin fins adjacent the first end and the second end are angled to align with a fluid flow direction for minimizing effects on a pressure drop of the heat sink; and a plurality of pin fins in a first column and a second column are connected by the plurality of bridged ribs, wherein the first column and the second column are spaced apart from the first end and the second end.

Description

CROSS-REFERENCE TO RELATED APPLICATION The present disclosure claims the benefit of Provisional Patent Application No. 63/716,940 filed on Nov. 6, 2024 and entitled “BRIDGED PIN ARRAY FOR IMPROVED STIFFNESS”, the contents of which are incorporated by reference in its entirety. TECHNICAL FIELD The present disclosure relates to pin fins for a heat sink for improving stiffness of the heat sink. In embodiments, the present disclosure relates to a heat sink with an array of pin fins, wherein the certain pin fins are connected by bridges. BACKGROUND The performance, lifespan, and safety of many electrical components are dependent on the temperature at which the electrical components operate and a build-up of heat can negatively affect these elements. The temperature of the electrical component may be affected by heat generated from the electrical component or its surrounding environment. Heat sinks are used to dissipate heat from electrical components or other heat-generating devices and prevent the negative effects from a build-up of heat. Some heat sinks use pin fins that extend outward from a base that is in thermal communication with the electrical component. As fluids (e.g., air, water, or the like) flow along the heat sink through the pin fins, the pin fins transfer the heat from the electrical component to the fluid, cooling the electrical component. One method of improving heat transfer is to reduce the thickness of the base of the heat sink. However, a reduction in the thickness of the base is limited by an overall stiffness of the heat sink, which ensures proper thermal contact with the electrical component and ensures no leakages during operation. SUMMARY According to an embodiment, a heat sink comprises a base extending from a first end to a second end and a plurality of pin fins extending from the base and arranged in a number of columns including a first column and a second column. Each pin fin includes a lower portion at or near the base and an opposing top portion spaced apart from the base. A plurality of bridged ribs includes a first plurality of bridged ribs, wherein the first plurality of bridged ribs each connect the top portion of one of the pin fins in the first column with the top portion of one of the pin fins in the second column. According to an embodiment, a heat sink comprises a base extending from a first end to a second end and a plurality of pin fins extending from the base wherein each pin fin includes a lower portion at or near the base and an opposing top portion spaced apart from the base. A plurality of bridges are angled to align with a fluid flow direction from the first end to the second end for minimizing effects on a pressure drop of the heat sink. A first column of the pin fins adjacent the first end, wherein the top portions of at least two of the pin fins in the first column are connected by a first of the plurality of bridges. A second column of the pin fins adjacent the second end, wherein the top portions of at least two of the pin fins in the second column are connected by a second of the plurality of bridges. According to an embodiment, a method of manufacturing a heat sink, the method comprising forming a plurality of pin fins that extend from a base of the heat sink, wherein each pin fin includes a lower portion at or near the base and an opposing top portion spaced apart from the base; forming a plurality of bridged ribs using an additive manufacturing process, wherein each of the plurality of bridged ribs each connect the top portion of one of the plurality of pin fins to the top portion of another of the plurality of pin fins; and wherein the plurality of bridged ribs increase an overall stiffness of the heat sink to resists bending and torsional moments. BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a top view of a heat sink including a plurality of bridges connecting a plurality of pin fins, according to a number of embodiments of the present disclosure; FIG. 2 is a cross-sectional view of the heat sink, wherein the plurality of bridges extend between top portions of the plurality of pin fins, according to an embodiment of the present disclosure; FIGS. 3A & 3B are enlarged, cross-sectional views of the heat sink shown in FIG. 1, wherein the plurality of bridges are angled to align with a flow direction of a fluid, according to an embodiment of the present disclosure; FIG. 3C is an enlarged, cross-sectional views of the heat sink shown in FIG. 1 wherein pin fins of at least two columns are connected by the plurality of pin fins, according to an embodiment of the present disclosure; and FIG. 3D is an enlarged top view of the heat sink shown in FIG. 1 showing the plurality of bridges connecting pin fins in a plurality of columns, according to an embodiment of the present disclosure. DETAILED DESCRIPTION Embodiments of the present disclosure are described herein. It is to be understood, however, that the disclosed embodiments are merely examples and other embodim