Fanless PC case by Original Twist
A totally silent Mini ITX PC case made from low-cost, off the shelf components with easy progression from prototype to large scale production.
The extruded fin case side is glued onto extruded aluminium corner sections; both are available from stock. The corner sections have slots to accept side panels in any material – the blue parts on this drawing could be marble for example.
The huge finned extrusion makes one side of the case. Heat transfer is via 6 heat pipes.
There are multiple SSD and HDD mounting options opposite the motherboard and also higher up the case.
The open case power supply (PSU) can be mounted internally and low down in the side channel extrusion. Any heat produced from this and the motherboard drives the updraft. There are no other components and no moving components at all.
The Magic Power (PSU) that fits the case is 80W so that much heat needs to be handled by the case. Any more power will need a Pico-PSU i.e. an external brick with internal ATX distribution leads. The case can cool up to 100W but most CPU chips will run under that level. The 6 heat pipes only use the top half of the case but extra heat pipes can be fitted down the side to bring the bottom of the big heat sink into play.
When standing up the tall chimney case draws air up through the bottom and expels it at the top so cooling is effected both inside and outside the case. The aluminium corner extrusions are part of the heat sink and are bonded on with heat transfer glue.
The finned heat pipe clamp on the CPU sits neatly in the airflow (splayed fins would be better) as do the heat pipes on their path to the side wall. The mother board, mounted at the bottom of the case, heats the air at the lowest point. Full height cock’s-comb RAM coolers also heat the air low down.
The heat pipes go across then down to the sink so the motherboard becomes upside-down when the PC is on its side with the heat sink uppermost.
Thermal performance calculations
The 6 heat pipes on the CPU block can remove at least 15W each and almost double that with the case in the upright position. Additional air flow through the case in this position will also remove some 10W from the CPU heat sink. So the removal side is good for over 100W but, of course, we need to dispose of this heat through the case.
The heat pipes only lie in half of the finned side and the manufacturer’s figures suggest a DegC/W of 0.45 for this length. With the CPU at 50C and a room at 22C we would be looking at 62W cooling power which would comfortably cool the 55W Intel Core i3 chips. Actually CPUs can run much hotter and the cooling power would be equally higher.
If the big heat sink side had additional heat pipes embedded along its entire length then the case would be able to remove around 80W so the i7 3770S at 65W could be accommodated and probably any 75W versions as well. It is hoped that the case will be able to lie flat for 55W chips and be good for practically anything while standing up or on a VESA mount. The added cooling power of the corner extrusions has not been taken into account in these calculations so real world performance should be much better than indicated. Theory is all very well but we can be sure by comparing with several existing silent PCs which work perfectly well. The Original Twist design has cooling surfaces of around 5 times that of the others so this should be the best of its kind. Some PCs have heat sinks; this PC is a heat sink!
Case size 124.5 x 240 x 350mm
The components dictate the shape.
Width – the I/O shield between 2 corners
40+44.5+40 = 124.5mm.
Side length – the finned extrusion between 2 corners
= 160+40+40= 240mm
Height/length – 170mm motherboard with HDD or SSD above – 350mm.
While it is big enough to house that monster cooling extrusion it is not as tall or deep as a typical small form factor PC and only slightly fatter.
The corner extrusions come with threaded inserts for the ends and these are used to bolt on the top and bottom plates.
4 big round feet enable the start button to be fitted in the base plate as well as the ‘power on’ LED and an angled power plug.
The radiused corners on the end plates match the case style.
Various Zotacs and the Compulabs Intense exemplify this silent PC slot but they are too expensive and none have enough cooling power for fast processors.
The Hdplex and Streacom cases both employ similar heat pipe cooling but with less cooling power and more complexity.
The Original Twist Fanless PC case delivers higher performance for a lower price.
The beautiful, contrasting black and aluminium finish looks truly modern making this ‘the computer you want’ and in every way better than ‘the computer you need’. Design flexibility allows the non cooling sides to be in various materials such as wood, aluminium or marble, none of which requires special tooling to produce.
This case provides excellent flexibility for product variation and expansion. The side panel with the I/O plate is long enough to mount DVD players or removable drive bays.
The computer is assembled with the finned side down. The heat pipes are cranked down once clear of the motherboard and are pressed into the machined slots in the side. After that the PSU channel and the opposite face plate are fitted along with the I/O plate.
Any SSDs or HDD are screwed onto the lid with their looms running neatly up the side so as not to impede airflow. This lid and attached corners then bolts on and finally the end plates hold it all together.
The bending of the heat pipes is fairly minimal but it is, none the less, quite critical. The sketch above shows how just 3 shapes of bend are needed to fit all six pipes. The yellow positions show where additional heat pipes could be laid to increase the effective case length. The pitch of the heat pipe slots on the heat sink have to be exact multiples of the pitch on the CPU block.
Our philosophy is simple. Cut waste and spend the difference on better components.
Designed in solid aluminium this PC brings you beautiful modern looks that reflect the quality and performance of the internals.
To bring you the best value for money with absolute reliability we removed all the moving parts. All discs and fans have been replaced by top quality components to bring you the best value, high performance, totally silent PC.
The Gigabyte motherboard is sheer indulgence – top quality with built in Wi-fi and built to last. It is WiDi compatible too so a wireless link to your TV is easy.
The 120 GB solid state drive gives exceptionally fast boot times and application loading.
Super fast USB-3 ports are available for you to plug in your external media storage devices or there is room inside for a hard drive with support for up to 3Tb.
The side plate holding the PSU can also house an optical media drive bay (41x146x185mm- dotted line on the drawing). A blue ray player built into your ‘Totally Brilliant Original Twist i3’ makes the perfect HTPC.
This case is not in production yet. If you would like to own this design and the business of producing it please use the Original Twist contact form. If I get enough ‘likes’ it will go into production.