Thermal bridge for electrical components

Abstract

The thermal bridge (200) includes an upper bridge assembly (202, 204) including an upper plate and a lower bridge assembly (202, 204) including a lower plate (400). The upper and lower panels (400) are segmented including a front section and a rear section meeting at a seam. An end of the lower plate (400) faces and is thermally coupled to the electrical component (102). The sides of some of the lower plates (400) face the sides of some of the upper plates such that the lower plates (400) are thermally docked with the upper plates. The thermal bridge (200) includes a spring element positioned between an upper bridge assembly (202, 204) and a lower bridge assembly (202, 204). The thermal bridge (200) includes a bridge frame (208) supporting upper and lower plates (400). The bridge frame (208) includes opening-limiting spars (236, 238) that engage the panels at the seam to limit deployment of the panels against each other against the opening force of the spring elements.

Description

TECHNICAL FIELD

[0001] The subject matter herein relates generally to heat dissipation for electrical components. BACKGROUND

[0002] It can be desirable to transfer thermal energy (or heat) away from designated components of a system or device. Some systems use electrical components, such as electrical connectors, to transmit data and / or power to and from different systems or devices. Some systems use electrical components, such as pluggable modules for transmitting data signals in the form of optical and / or electrical signals over a communication cable(s). Some systems use electrical components, such as integrated circuits, for controlling the system. The electrical components define a source of heat generation within the system.

[0003] A common challenge faced by developers of electrical systems is thermal management. Thermal energy generated by electrical components within a system can reduce performance or even damage components of the system. To dissipate the thermal energy, the system includes thermal components, such as heat sinks, that engage the heat source, absorb the thermal energy from the heat source, and transfer the thermal energy away. The heat sinks are typically thermally coupled to another thermal component at yet another thermal interface. The components lose efficiency at each thermal interface. Additionally, it is difficult to achieve efficient thermal coupling at the interface due to limited thermal interface area and variations in surface, such as due to surface flatness of the interface surface.

[0004] Accordingly, there is a need for a thermal transfer assembly that efficiently transfers thermal energy away from electrical components. SUMMARY

[0005] According to the present invention, a thermal bridge is provided that includes an upper bridge assembly that includes a plurality of upper plates arranged in an upper plate stack. Each upper plate is segmented, including an upper front segment at a front end of the upper plate and an upper rear segment at a rear end of the upper plate. Each upper plate has an upper joint between the upper front segment and the upper rear segment. Each upper plate has a side between the front end and the rear end. Each upper plate has an inner end and an outer end. The thermal bridge includes a lower bridge assembly that includes a plurality of lower plates arranged in a lower plate stack. Each lower plate is segmented, including a lower front segment at a front end of the lower plate and a lower rear segment at a rear end of the lower plate. Each lower plate has a lower joint between the lower front segment and the lower rear segment. Each lower plate has a side between the front end and the rear end. Each lower plate has an inner end and an outer end. The outer ends of the lower plates are configured to face and thermally couple to electrical components. The sides of some of the lower plates face the sides of some of the upper plates to thermally interface the lower plates with the upper plates. The thermal bridge includes a spring element positioned between the upper bridge assembly and the lower bridge assembly. The spring element includes an upper spring member that engages the upper plates to bias the upper plates generally away from the lower plates with an opening force. The spring element includes a lower spring member that engages the lower plates to bias the lower plates generally away from the upper plates with the opening force. The thermal bridge includes a bridge frame that supports the upper plates in the upper plate stack and supports the lower plates in the lower plate stack. The bridge frame includes an upper open containment spar that engages the upper plates at the upper joints to limit the upper plates from unfolding from the lower plates against the opening force of the spring element. The bridge frame includes a lower open containment spar that engages the lower plates at the lower joints to limit the lower plates from unfolding from the upper plates against the opening force of the spring element. BRIEF DESCRIPTION OF DRAWINGS

[0006] Figure 1 is a front perspective view of a communication system and a thermal bridge for dissipating heat from at least one electrical component of the communication system, in accordance with an exemplary embodiment.

[0007] Figure 2 is an exploded view of a thermal bridge, in accordance with an exemplary embodiment.

[0008] Figure 3 various plate pairs are shown, including upper and lower plates arranged relative to one another in the plate pairs, in accordance with exemplary embodiments.

[0009] Figure 4 various plate pairs are shown, including upper and lower plates arranged relative to one another in the plate pairs, in accordance with exemplary embodiments.

[0010] Figure 5 is a close-up view of a portion of a thermal bridge, in accordance with an exemplary embodiment.

[0011] Figure 6 is a close-up view of a portion of a thermal bridge, in accordance with an exemplary embodiment. DETAILED DESCRIPTION

[0012] Figure 1 is a front perspective view of a communication system 100 and a thermal bridge 200 for dissipating heat from at least one electrical component 102 of the communication system 100, in accordance with an example embodiment. The thermal bridge 200 is configured to thermally couple to the electrical component 102 at a lower thermal interface 104 at a bottom of the thermal bridge 200. In example embodiments, a heat transfer device 106 is provided to dissipate heat from the thermal bridge 200. For example, the thermal bridge 200 is configured to thermally couple to the heat transfer device 106 at an upper thermal interface 108. The thermal bridge 200 thermally connects the electrical component 102 and the heat transfer device 106 to dissipate heat from the electrical component 102. The heat transfer device 106 can be a heat sink, such as a finned heat sink, configured to be air cooled by transferring heat to a passing air flow. In other various embodiments, the heat transfer device 106 can be a heat sink, a cold plate with liquid cooling, etc.

[0013] In example embodiments, the thermal bridge 200 is compressible between the electrical component 102 and the heat transfer device 106. In example embodiments, the lower thermal interface 104 conforms to a shape of the electrical component 102 and the upper thermal interface 108 conforms to a shape of the heat transfer device 106 for efficient heat transfer therebetween. For example, the thermal bridge 200 can be a stacked plate-like structure in which individual plates are movable relative to one another to conform to the electrical component 102 and the heat transfer device 106. In example embodiments, the thermal bridge 200 is segmented in a longitudinal direction into one or more segments 201 that are independently movable relative to one another and conform to the electrical component 102 and / or the heat transfer device 106. For example, each of the plates is segmented into a front segment and a rear segment and possibly one or more intermediate segments between the front and rear segments.

[0014] In example embodiments, the electrical component 102 is mounted to a circuit board 110. In various embodiments, the electrical component 102 can be a communication connector, such as a receptacle connector, header connector, plug connector, or another type of communication connector. In other various embodiments, the electrical component 102 can be an electronic package, such as an integrated circuit. In other various embodiments, the electrical component 102 can be a pluggable module, such as an I / O transceiver module. Other types of electrical components can be provided in alternative embodiments.

[0015] In an example embodiment, the thermal bridge 200 includes an upper bridge assembly 202, a lower bridge assembly 204, one or more spring elements 206 between the upper and lower bridge assemblies 202, 204, and a bridge frame 208 for holding the upper and lower bridge assemblies 202, 204 together. The lower bridge assembly 204 is configured to thermally engage the electrical component 102. The upper bridge assembly 202 is configured to dissipate heat to an external environment and / or to the heat transfer device 106. The upper bridge assembly 202 is in thermal communication with the lower bridge assembly 204 and dissipates heat away from the lower bridge assembly 204 to cool the electrical component 102. In an example embodiment, the upper bridge assembly 202 is segmented into a plurality of segments 201 (e.g., a front segment and a rear segment) and the lower bridge assembly 204 is segmented into a plurality of segments 201 (e.g., a front segment and a rear segment).

[0016] The spring element(s) 206 bias the upper and lower bridge assemblies 202, 204 apart. In an example embodiment, the spring elements 206 interface with the segments 201 of the upper and lower bridge assemblies 202, 204 to spread the upper and lower segments 201 apart from each other with an opening force. The upper and lower bridge assemblies 202, 204 are compressible relative to each other. For example, the upper and lower segments 201 of the bridge assemblies 202, 204 are compressible between the electrical component 102 and the heat transfer device 106. The spring elements 206 are compressible between the upper and lower segments 201.

[0017] The bridge frame 208 provides support for the upper and lower bridge assemblies 202, 204. For example, the bridge frame 208 provides support for the upper and lower segments 201 of the bridge assemblies 202, 204. The bridge frame 208 extends around an outer perimeter of the thermal bridge 200, such as along the sides and ends, leaving the top and bottom to form thermal interfaces with the electrical component 102 and the heat transfer device 106. In an example embodiment, the bridge frame 208 provides internal support through the bridge assemblies 202, 204, such as through the segments 201. The internal support maintains the relative positions of the front and rear segments 201, such as by limiting motion to a limited amount of relative motion, to allow the segments 201 to conform to the electrical component 102 and the heat transfer device 106.

[0018] In an example embodiment, the spring elements 206 press the segments 201 of the upper bridge assembly 202 outward against the bridge frame 208 in a first biasing direction (e.g., upward) and the spring elements 206 press the segments 201 of the lower bridge assembly 204 outward against the bridge frame 208 in a second biasing direction (e.g., downward). The upper and lower bridge assemblies 202, 204 can be held by the bridge frame 208 in a manner that allows a limited amount of floating motion of the upper and lower bridge assemblies 202, 204 relative to the bridge frame 208.

[0019] Figure 2is an exploded view of a thermal bridge 200 according to an example embodiment. The thermal bridge 200 includes an upper bridge assembly 202 and a lower bridge assembly 204. Spring elements 206 are located between the upper and lower bridge assemblies 202, 204. A bridge frame 208 is configured to hold the upper and lower bridge assemblies 202, 204.

[0020] In example embodiments, the thermal bridge 200 is a parallelepiped (e.g., generally box-shaped). For example, the thermal bridge 200 includes a top 280, a bottom 282, a front 284, a back 286, a first side 290, and a second side 292. The thermal bridge 200 extends longitudinally between the front 284 and the back 286. In example embodiments, the upper bridge assembly 202 and the lower bridge assembly 204 are segmented into a plurality of segments 201 in the longitudinal direction between the front 284 and the back 286. The top 280 can be generally planar for thermal connection with the heat transfer device 106. The bottom 282 can be generally planar for thermal connection with the electrical component 102. The upper bridge assembly 202 and the lower bridge assembly 204 have a large surface area along the top 280 and the bottom 282 for thermal connection with the heat transfer device 102 and the electrical component 106.

[0021] The bridge frame 208 is a frame structure for holding the thermal bridge 200 together. The bridge frame 208 can extend along the front 284, the back 286, the first side 290, and the second side 292 to hold the upper bridge assembly 202 and the lower bridge assembly 204 together in an interior of the bridge frame 208. In example embodiments, no portion of the bridge frame 208 extends along the top 280 or the bottom 282. The bridge frame 208 is distanced from the upper thermal interface 108 such that the bridge frame 208 does not obstruct the upper thermal interface 108 and provides a large amount of available outer surface area for interfacing with the heat transfer device 106. The bridge frame 208 is distanced from the lower thermal interface 104 such that the bridge frame 208 does not obstruct the lower thermal interface 104 and provides a large amount of available outer surface area for interfacing with the electrical component 102.

[0022] In example embodiments, the bridge assemblies 202, 204 each include a plurality of plates arranged together in a plate stack. In example embodiments, each of the plates is segmented in a longitudinal direction between a front portion 284 and a rear portion 286 into a plurality of plate segments 201. The plates and plate segments 201 are interleaved with one another for thermal communication between the upper bridge assembly 202 and the lower bridge assembly 204. Individual plates and plate segments 201 are movable relative to one another so that the plates can be individually articulated to conform to the electrical component 102 and / or the heat transfer device 106. For example, individual plates can conform to the electronic component 102 at the lower thermal interface 104 to improve contact and / or proximity between the thermal bridge 200 and the electronic component 102, and / or individual plates can conform to the heat transfer device 106 at the upper thermal interface 108 to improve contact and / or proximity between the thermal bridge 200 and the heat transfer device 106. Gaps or spaces can be provided between the plates and plate segments 201 of the upper and lower bridge assemblies 202, 204 to allow for compression movement of the spring elements 206 between the bridge assemblies 202, 204.

[0023] In example embodiments, the upper bridge assembly 202 includes a plurality of upper plates 300 arranged in an upper plate stack 302. Each upper plate 300 has a side 304 extending between an inner end 306 and an outer end 308 of the upper plate 300. The inner end 306 faces the lower bridge assembly 204. The outer end 308 faces outward, such as toward the heat transfer device 106. Optionally, various upper plates 300 can have different shapes, for example different heights and / or different features between the inner end 306 and the outer end 308. In example embodiments, each upper plate 300 includes an upper front segment 310 and an upper rear segment 312. An upper joint 314 is defined between the upper front segment 310 and the upper rear segment 312. The upper front segment 310 and the upper rear segment 312 are connected together across the upper joint 314 by the bridge frame 208 to control relative movement between the upper front segment 310 and the upper rear segment 312. Additional intermediate segments (not shown) can be arranged between the upper front segment 310 and the upper rear segment 312 with additional upper joints therebetween.

[0024] In example embodiments, the lower bridge assembly 204 includes a plurality of lower plates 400 arranged in a lower plate stack 402. Each lower plate 400 has a side 404 extending between an inner end 406 and an outer end 408 of the lower plate 400. The inner end 406 faces the upper bridge assembly 202. The outer end 408 faces outward, such as toward the electrical component 102 (as shown in FIG. 1) and / or the upper bridge assembly 202. Optionally, various lower plates 400 can have different shapes, for example different heights and / or different features between the inner end 406 and the outer end 408. In example embodiments, each lower plate 400 includes a lower front segment 410 and a lower rear segment 412. A lower joint 414 is defined between the lower front segment 410 and the lower rear segment 412. The lower front segment 410 and the lower rear segment 412 are connected together across the lower joint 414 by the bridge frame 208 to control relative movement between the lower front segment 410 and the lower rear segment 412. Additional intermediate segments (not shown) can be arranged between the lower front segment 410 and the lower rear segment 412 with additional lower joints therebetween. Figure 1The various lower plates 400 can optionally have different shapes and / or heights between the inner end 406 and the outer end 408. In an example embodiment, each lower plate 400 includes a lower front segment 410 and a lower back segment 412. A lower joint 414 is defined between the lower front segment 410 and the lower back segment 412. The lower front segment 410 and the lower back segment 412 are connected together across the lower joint 414 by the bridge frame 208 to control relative movement between the lower front segment 410 and the lower back segment 412. Additional middle segments (not shown) can be disposed between the lower front segment 410 and the lower back segment 412 with additional lower joints therebetween.

[0025] In an example embodiment, the upper plates 300 and the lower plates 400 are arranged in plate pairs 230. Each plate pair 230 includes one of the upper plates 300 and one of the lower plates 400. The plates 300, 400 in the plate pairs 230 are aligned with each other. For example, the upper plates 300 and the lower plates 400 are vertically stacked with the upper plates 300 above the lower plates 400. The plate pairs 230 are stacked together to form the stacked arrangement of the thermal bridge 200. The bridge frame 208 holds the plate pairs 230 in the stacked arrangement. The spring elements 206 are configured to be positioned between the upper and lower plates 300, 400 and to expand the upper plates 300 away from the lower plates 400.

[0026] Further reference is made to Figure 3 and Figure 4 , Figure 3 and Figure 4 Various plate pairs 230 are shown, including upper plates 300 and lower plates 400 arranged relative to each other in the plate pairs 230. Figure 3 A first pair 232 is shown. Figure 4 A second pair 234 is shown. The upper plates 300 of the first pair 232 are different from the upper plates 300 of the second pair 234. The lower plates 400 of the first pair 232 are different from the lower plates 400 of the second pair 234.

[0027] In an example embodiment, the upper plates 300 include upper spring pockets 316 that receive the spring elements 206. The upper spring pockets 316 can be located near the front end and the back end. The upper spring pockets 316 can be located at the upper joint 314 to allow the spring elements 206 to engage the upper front segment and the upper back segment 310, 312.

[0028] In an example embodiment, the lower plates 400 include lower spring pockets 416 that receive the spring elements 206. The lower spring pockets 416 can be located near the front end and the back end. The lower spring pockets 416 can be located at the lower joint 414 to allow the spring elements 206 to engage the lower front segment 410 and the lower back segment 412.

[0029] In example embodiments, the upper plates 300 include upper stop tabs 318 for positioning the upper plates 300 relative to the bridge frame 208. For example, the upper stop tabs 318 are disposed at the front and rear ends of the upper plates 300 to interface with the bridge frame 208, such as at the front portion 284 and the rear portion 286. The upper stop tabs 318 engage the bridge frame 208 to position the upper plates 300 in the upper plate stack 302. The upper stop tabs 318 limit vertical movement of the upper plates 300 so as to limit the upper plates 300 from unfolding from the lower plates 400. The spring elements 206 can press the upper plates 300 outward (e.g., upward) until the upper stop tabs 318 bottom out against the bridge frame 208.

[0030] In example embodiments, the lower plates 400 include lower stop tabs 418 for positioning the lower plates 400 relative to the bridge frame 208. For example, the lower stop tabs 418 are disposed at the front and rear ends of the lower plates 400 to interface with the bridge frame 208, such as at the front portion 284 and the rear portion 286. The lower stop tabs 418 engage the bridge frame 208 to position the lower plates 400 in the lower plate stack 402. The lower stop tabs 418 limit vertical movement of the lower plates 400 so as to limit the lower plates 400 from unfolding from the upper plates 300. The spring elements 206 can press the lower plates 400 outward (e.g., upward) until the lower stop tabs 418 bottom out against the bridge frame 208.

[0031] In example embodiments, the upper plates 300 include upper bridge plates 320 Figure 3 ) and upper spacer plates 322 Figure 4 . The upper spacer plates 322 are located between the upper bridge plates 320. Both the upper bridge plates 320 and the upper spacer plates 322 include the upper stop tabs 318. In example embodiments, the lower plates 400 include lower bridge plates 420 Figure 4 ) and lower spacer plates 422 Figure 3 . The lower spacer plates 422 are located between the lower bridge plates 420. Both the lower bridge plates 420 and the lower spacer plates 422 include the lower stop tabs 418.

[0032] Referring to Figure 3 each upper bridge plate 320 includes a base 330 at the outer end 308 and an overlap region 332 at the inner end 306 that is configured to overlap an adjacent lower plate 400 of the lower bridge assembly 204. The overlap region 332 extends downward from the base 330. The upper bridge plate 320 is wider at the overlap region 332 than along the base 330. The overlap region 332 provides a large surface area that is configured to thermally couple to the adjacent lower plate 400. The overlap region 332 is located between the upper spring pockets 316. In the illustrated embodiment, the upper front section 310 includes a corresponding overlap region 332 and the upper rear section 312 includes a corresponding overlap region 332.

[0033] Each lower spacer plate 422 includes a spacer base 450 at the outer end 408 and a recess 452 formed in the spacer base 450. The recess 452 is aligned with and configured to receive the corresponding overlapping region 332 of the upper plate 300. The lower spacer plate 422 is thinner along the recess 452 than along the spacer base 450. The recess 452 is located between the lower spring recesses 416. In the illustrated embodiment, the lower front section 410 includes a corresponding recess 452 and the lower rear section 412 includes a corresponding recess 452.

[0034] With reference to Figure 4 Each upper spacer plate 322 includes a spacer base 350 at the outer end 308 and a recess 352 formed in the spacer base 350. The recess 352 is aligned with and configured to receive the overlapping region of the lower plate 400. The upper spacer plate 322 is thinner along the recess 352 than along the spacer base 350. The recess 352 is located between the upper spring recesses 316. In the illustrated embodiment, the upper front section 310 includes a corresponding recess 352 and the upper rear section 312 includes a corresponding recess 352.

[0035] Each lower bridge plate 420 includes a base 430 at the outer end 408 and an overlapping region 432 at the inner end 406 configured to overlap an adjacent upper plate 300 of the upper bridge assembly 202. The overlapping region 432 extends upward from the base 430. The lower bridge plate 420 is wider at the overlapping region 432 than along the base 430. The overlapping region 432 provides a large surface area configured to thermally couple to an adjacent upper plate 300, such as the overlapping region 332. The overlapping region 432 is located between the lower spring recesses 416. In the illustrated embodiment, the lower front section 410 includes a corresponding overlapping region 432 and the lower rear section 412 includes a corresponding overlapping region 432.

[0036] With reference back to Figure 2The spring element 206 is separate and discrete from the upper and lower bridge assemblies 202, 204. The spring element 206 can be a stamped formed part. The spring element 206 is manufactured from a thin metal material such that the spring element 206 is flexible. In the exemplary embodiment, the spring element 206 includes an upper spring member 210 and a lower spring member 220. The upper spring member 210 engages the upper plate 300 to bias the upper plate 300 with an opening force generally away from the lower plate 400. The lower spring member 220 engages the lower plate 400 to bias the lower plate 400 with an opening force generally away from the upper plate 300. The upper spring member 210 can be separate and discrete from the lower spring member 220 and coupled to the lower spring member 220 to form the spring element 206. In the illustrated embodiment, the spring plate 210 is a cupped plate spring arranged back-to-back to form the spring element 206. For example, the spring element 206 can be X-shaped. Other types of spring elements 206 can be used in alternative embodiments, such as coil springs, plate springs, C-channel springs, etc.

[0037] The upper spring member 210 includes a front spring member 212 and a rear spring member 214. The upper spring member 210 can include a center panel 216 between the front and rear spring members 212, 214. Distal ends of the front and rear spring members 212, 214 are configured to engage the upper front and rear sections 310, 312 of the upper plate 300, respectively. The spring members 212, 214 can include individual spring fingers.

[0038] The lower spring member 220 includes a front spring member 222 and a rear spring member 224. The lower spring member 220 can include a center panel 226 between the front and rear spring members 222, 224. Distal ends of the front and rear spring members 222, 224 are configured to engage the lower front and rear sections 310, 312 of the lower plate 300, respectively. The spring members 222, 224 can include individual spring fingers.

[0039] The spring element 206 is configured to be received in the upper and lower spring pockets 316, 416. The spring element 206 is positioned between the upper and lower plates 300, 400. The spring element 206 is compressible between the upper and lower plates 300, 400. Any number of spring elements 206 can be provided depending on the amount of spring force desired, the spacing between the upper and lower plates 300, 400, the length of the upper and lower plates 300, 400, and the number of sections of the upper and lower plates 300, 400. In the illustrated embodiment, the thermal bridge 200 includes a front spring element proximate the front portion 284, a rear spring element proximate the rear portion 286, and a center spring element at the joint between the front and rear sections of the plates.

[0040] In example embodiments, the bridge frame 208 is fabricated from a plurality of frame elements that can be connected together to form a support structure for the upper and lower segments 201, 201 of the upper and lower plates 300, 400. For example, the frame elements can surround an outer periphery of the plate stack. The frame elements can pass through an interior of the plate stack to hold the segments 201. In example embodiments, the bridge frame 208 includes a front rail 240, a rear rail 250, a first side rail 260 extending between the front and rear rails 240, 250, and a second side rail 270 extending between the front and rear rails 240, 250. In example embodiments, the bridge frame 208 includes an upper opening containment spar 236 and a lower opening containment spar 238. The upper and lower opening containment spars 236, 238 extend between the first and second side rails 260, 270 across the plate stack. The upper opening containment spar 238 engages the upper plate 300 to resist the opening force of the spring elements 206 to limit the upper plate 300 from unfolding from the lower plate 400. The lower opening containment spar 238 engages the lower plate 400 to resist the opening force of the spring elements 206 to limit the lower plate 400 from unfolding from the upper plate 300. In example embodiments, the upper and lower opening containment spars 236, 238 are located at the seams 314, 414 to support the front and rear segments 201 relative to each other.

[0041] The front rail 240 includes a main panel 242 and upper and lower flanges 244, 246 extending from the main panel 242. The front rail 240 can be formed from sheet metal stamping. A space 248 is defined between the flanges 244, 246 that receives the end portions of the plates 300, 400. For example, the upper and lower containment tabs 318, 418 at the front end of the plates 300, 400 are received in the space 248. The flanges 244, 246 are configured to capture the upper and lower containment tabs 318, 418 in the space 248. The flanges 244, 246 limit the unfolding of the upper and lower plates 300, 400. The upper containment tab 318 at the front end engages the upper flange 244 to limit the unfolding (upward movement) of the upper plate 300 at the front end. The lower containment tab 418 at the front end engages the lower flange 246 to limit the unfolding (downward movement) of the lower plate 400 at the front end. The front spring elements 206 are located at the front end of the plates 300, 400, such as proximate the front rail 240, to bias the segments 201 of the plates 300, 400 apart from each other.

[0042] The rear rail 250 includes a main panel 252 and upper and lower flanges 254, 256 extending from the main panel 252. The rear rail 250 can be formed by sheet metal stamping. A space 258 is defined between the flanges 254, 256 that receives the end of the panels 300, 400. For example, the upper and lower limit tabs 318, 418 at the rear end of the panels 300, 400 are received in the space 258. The flanges 254, 256 are configured to capture the upper and lower limit tabs 318, 418 in the space 258. The flanges 254, 256 limit the spread of the upper and lower panels 300, 400. The upper limit tab 318 at the rear end engages the upper flange 254 to limit the spread (upward movement) of the upper panel 300 at the rear end. The lower limit tab 418 at the rear end engages the lower flange 256 to limit the spread (downward movement) of the lower panel 400 at the rear end. The rear spring element 206 is located at the rear end of the panels 300, 400, such as proximate the rear rail 250, to bias the segments 201 of the panels 300, 400 apart from each other.

[0043] The first side rail 260 includes a main panel 262 and a connecting tab 264 extending from the main panel 262 to connect the first side rail 260 to the front and rear rails 240, 250. The connecting tab 264 can be brazed or welded to the front and rear rails 240, 250. The first side rail 260 can be formed by sheet metal stamping. The main panel 262 includes an opening 266 that receives the locating tab at the end of the spring element 206. The main panel 262 includes a slot 268 that receives the upper and lower open limit spars 236, 238. The ends of the upper and lower open limit spars 236, 238 are supported by the first side rail 260 within the slot 268. The upper and lower open limit spars 236, 238 can be brazed or welded to the first side rail 260 to secure the upper and lower open limit spars 236, 238 to the first side rail 260.

[0044] The second side rail 270 includes a main panel 272 and a connecting tab 274 extending from the main panel 272 to connect the second side rail 270 to the front and rear rails 240, 250. The connecting tab 274 can be brazed or welded to the front and rear rails 240, 250. The second side rail 270 can be formed by sheet metal stamping. The main panel 272 includes an opening (not shown) that receives the locating tab at the end of the spring element 206. The main panel 272 includes a slot (not shown) that receives the upper and lower open limit spars 236, 238. The ends of the upper and lower open limit spars 236, 238 are supported by the second side rail 270 within the slot. The upper and lower open limit spars 236, 238 can be brazed or welded to the second side rail 270 to secure the upper and lower open limit spars 236, 238 to the second side rail 270.

[0045] In the example embodiment, the upper open-limit spar 236 is a flat planar spar configured to pass through the upper panel 300. The upper open-limit spar 236 can be generally rectangular in cross-section. For example, opposite ends of the flat spar can be received in the upper front section 310 and the upper rear section 312. In the example embodiment, the upper open-limit spar 236 is located at the upper joint 314. The upper front and rear sections 310, 312 are connected together across the upper joint 314 by the upper open-limit spar 236 to control relative movement between the upper front and rear sections 310, 312. In the example embodiment, each upper front section 310 includes an upper slot 324 and each upper rear section 312 includes an upper slot 326. The upper slots 324, 326 are generally aligned with each other. The upper slot 326 opens to the upper joint 314. The upper slots 324, 326 receive the upper open-limit spar 236. In the example embodiment, the upper slots 324, 326 are oversized relative to the upper open-limit spar 236 so that a gap is formed in the upper slots 324, 326 that is sized to allow floating movement of the upper front section 310 and the upper rear section 312 in the upper slots 324, 326 to allow the upper panel 300 to compress and expand relative to the lower panel 400 and to allow the upper panel 300 to conform to the heat transfer device 106. The upper open-limit spar 236 can be stamped from sheet metal. However, other types of connecting elements can be used in alternative embodiments. For example, the connecting elements can be round or square pins that can be manufactured by an extrusion process. Other types of connecting elements can be used in alternative embodiments.

[0046] In the example embodiment, the lower open containment spar 238 is a flat planar spar configured to pass through the lower plate 400. The lower open containment spar 238 can be generally rectangular in cross-section. For example, opposite ends of the flat spar can be received in the lower front section 410 and the lower rear section 412. In the example embodiment, the lower open containment spar 238 is located at the lower joint 414. The lower front section and the lower rear section 410, 412 are connected together across the lower joint 414 by the lower open containment spar 238 to control relative movement between the lower front section and the lower rear section 410, 412. In the example embodiment, each lower front section 410 includes a lower slot 424 and each lower rear section 412 includes a lower slot 426. The lower slots 424, 426 are generally aligned with each other. The lower slot 426 opens to the lower joint 414. The lower slots 424, 426 receive the lower open containment spar 238. In the example embodiment, the lower slots 424, 426 are oversized relative to the lower open containment spar 238 so that a gap is formed in the lower slots 424, 426 that is sized to allow floating movement of the lower front section 410 and the lower rear section 412 in the lower slots 424, 426 so as to allow compression and expansion of the lower plate 400 relative to the upper plate 300 and to allow the lower plate 400 to conform to the electrical components 102. The lower open containment spar 238 can be stamped from sheet metal. However, other types of connecting elements can be used in alternative embodiments. For example, the connecting elements can be round or square pins that can be manufactured by an extrusion process. Other types of connecting elements can be used in alternative embodiments.

[0047] When assembled, the spring elements 206 are located between the upper and lower plates 300, 400. The spring elements 206 bias the upper and lower plates 300, 400 apart. For example, the spring elements 206 bias the sections 210 apart. The upper and lower open containment spars 236, 238 control the positioning of the upper and lower plates 300, 400 in the plate stack. For example, the upper and lower open containment spars 236, 238 limit the spread of the upper and lower plates 300, 400 at predetermined outer limits. The spring elements 206 are compressible between the upper plate 300 and the lower plate 400, for example when mated with the electrical components 102 and the heat transfer device 106.

[0048] When assembled, the lower spacer plate 422 is aligned with the upper bridge plate 320 and the upper spacer plate 322 is aligned with the lower bridge plate 420. The overlap region 332 is vertically aligned with the pocket 434. Similarly, the overlap region 432 is vertically aligned with the pocket 334. The overlap regions 332, 432 are arranged side-by-side within the upper and lower stacks to allow heat transfer between the upper and lower plates 300, 400.

[0049] The spring elements 206 are received in the gaps between the upper and lower segments 201 of the plates 300, 400. The spring elements 206 press the segments of the upper plate 300 in an upward biasing direction and press the segments of the lower plate 400 in a downward biasing direction. The spring elements 206 tend to separate the segments of the upper plate 300 from the segments of the lower plate 400 to press the upper plate 300 into thermal engagement with the heat transfer device 106 and press the lower plate 400 into thermal engagement with the electrical component 102. The segments 201 of the upper and lower plates 300, 400 are independently movable relative to each other and relative to the adjacent segments 201 of the upper and lower plates 300, 400. The segments of the upper plate 300 are configured to float relative to the segments of the lower plate 400, and the spring elements 206 allow the floating movement of the upper and lower plates 300, 400. In this way, the upper mating interface conforms to the heat transfer device 106, and the lower mating interface conforms to the electrical component 102.

[0050] The bridge frame 208 holds the upper and lower plates 300, 400. The upper and lower open containment wings 236, 238 extend between the side rails 260, 270 and through the upper and lower slots 326, 426 (e.g., through the entire stack). The containment tabs that define the slots 326, 426 interface with the upper and lower open containment wings 236, 238 to position the upper and lower plates 300, 400 relative to each other and define the outer deployment limits of the upper and lower plates 300, 400 relative to each other. For example, the containment tabs form stop surfaces that engage the upper and lower open containment wings 236, 238. The upper and lower open containment wings 236, 238 limit the deployment of the upper and lower plates 300, 400 from each other. The spring elements 206 press the upper plate 300 upward until the stop surfaces engage the upper open containment wing 238. The spring elements 206 press the lower plate 400 downward until the stop surfaces engage the lower open containment wing 238.

[0051] Figure 5 is a zoomed-in view of a portion of the thermal bridge 200 according to an example embodiment. The thermal bridge 200 includes an upper bridge assembly 202 and a lower bridge assembly 204 with spring elements 206 located between the upper and lower bridge assemblies 202, 204. The bridge frame 208 is configured to hold the upper and lower bridge assemblies 202, 204, for example, at the seams 314, 414 between the segmented plates 300, 400 of the upper and lower bridge assemblies 202, 204. In example embodiments, the spring elements 206 are located between the plate segments 201 at the seams 314, 414.

[0052] In example embodiments, the bridge frame 208 is used to hold the plates 300, 400 in a plate stack. The bridge frame 208 is used to hold the spring elements 206. Figure 5A portion of the side rail 270 is shown supporting the upper open containment spar 236 and the lower open containment spar 238. For example, the side rail 270 includes a slot 278 that receives the upper and lower open containment spars 236, 238. The upper and lower open containment spars 236, 238 can be brazed or welded to the second side rail 270 to secure the upper and lower open containment spars 236, 238 to the second side rail 270.

[0053] The upper and lower open containment spars 236, 238 extend through the stack of panels. The upper open containment spar 238 engages the upper panel 300 to resist the opening force of the spring element 206 to limit the upper panel 300 from unfolding from the lower panel 400. The lower open containment spar 238 engages the lower panel 400 to resist the opening force of the spring element 206 to limit the lower panel 400 from unfolding from the upper panel 300. In an example embodiment, the upper and lower open containment spars 236, 238 are located at the seams 314, 414 to support the front and rear sections 201 relative to each other.

[0054] In an example embodiment, the upper open containment spar 236 is located at the upper seam 314. The upper front and rear sections 310, 312 are connected together across the upper seam 314 by the upper open containment spar 236 to control the relative motion between the upper front and rear sections 310, 312. In an example embodiment, the upper slots 324, 326 of the upper front and rear sections 310, 312 receive the upper open containment spar 236. In an example embodiment, the upper slots 324, 326 are oversized relative to the upper open containment spar 236 to form gaps 325, 327 in the upper slots 324, 326 that are sized to allow floating motion of the upper front and rear sections 310, 312 relative to the upper open containment spar 236 to allow the upper panel 300 to compress and expand relative to the lower panel 400 and to allow the upper panel 300 to conform to the heat transfer device 106.

[0055] In an example embodiment, the lower open containment spar 238 is located at the lower seam 414. The lower front and rear sections 410, 412 are connected together across the lower seam 414 by the lower open containment spar 238 to control the relative motion between the lower front and rear sections 410, 412. In an example embodiment, the lower slots 424, 426 of the lower front and rear sections 410, 412 receive the lower open containment spar 238. In an example embodiment, the lower slots 424, 426 are oversized relative to the lower open containment spar 238 to form gaps 425, 427 in the lower slots 424, 426 that are sized to allow floating motion of the lower front and rear sections 410, 412 relative to the lower open containment spar 238 to allow the lower panel 400 to compress and expand relative to the upper panel 300 and to allow the lower panel 400 to conform to the electrical component 102.

[0056] When assembled, the spring element 206 is positioned between the upper and lower plates 300, 400. The spring element 206 biases the upper and lower plates 300, 400 apart. For example, the spring element 206 biases the segments 210 apart. The upper and lower open containment wings 236, 238 control the positioning of the upper and lower plates 300, 400 in the plate stack. For example, the upper and lower open containment wings 236, 238 limit the spread of the upper and lower plates 300, 400 at predetermined outer limits. The spring element 206 is compressible between the upper and lower plates 300, 400, such as when mated with the electrical component 102 and the heat transfer device 106. The spring element 206 is received in the gap between the upper and lower segments 201 of the plates 300, 400. The spring element 206 presses the segments of the upper plate 300 in an upward biasing direction and presses the segments of the lower plate 400 in a downward biasing direction. The spring element 206 tends to separate the segments of the upper plate 300 from the segments of the lower plate 400 to press the upper plate 300 into thermal interface with the heat transfer device 106 and press the lower plate 400 into thermal engagement with the electrical component 102. The segments 201 of the upper and lower plates 300, 400 are independently movable relative to each other and relative to the adjacent segments 201 of the upper and lower plates 300, 400. The segments of the upper plate 300 are configured to float relative to the segments of the lower plate 400, and the spring element 206 allows the floating movement of the upper and lower plates 300, 400. In this way, the upper mating interface conforms to the heat transfer device 106 and the lower mating interface conforms to the electrical component 102.

[0057] The bridge frame 208 holds the upper and lower plates 300, 400. The upper and lower open containment wings 236, 238 extend between the side rails 260, 270 and through the upper and lower slots 326, 426 (e.g., through the entire stack). The containment tabs that define the slots 326, 426 interface with the upper and lower open containment wings 236, 238 to position the upper and lower plates 300, 400 relative to each other and define outer spread limits of the upper and lower plates 300, 400 relative to each other. The upper and lower open containment wings 236, 238 limit the spread of the upper and lower plates 300, 400 from each other. The spring element 206 presses the upper plate 300 upward until the stop surface or flange forming the slot 324, 326 engages the upper open containment wing 236. The spring element 206 presses the lower plate 400 downward until the stop surface or flange forming the slot 424, 426 engages the lower open containment wing 238.

[0058] Figure 6FIG2 is an enlarged view of a portion of a thermal bridge 200 according to an exemplary embodiment. Thermal bridge 200 includes an upper bridge assembly 202 and a lower bridge assembly 204, with spring elements 206 positioned between the upper and lower bridge assemblies 202, 204. A bridge frame 208 is configured to hold the upper and lower bridge assemblies 202, 204, such as at joints 314, 414 between the segmented panels 300, 400 of the upper and lower bridge assemblies 202, 204. In the exemplary embodiment, spring elements 206 are positioned between the panel segments 201 at the joints 314, 414. Figure 6 The thermal bridge 200 shown is similar to Figure 5 The thermal bridge 200 is shown. However, in Figure 6 In the embodiment shown, the gaps in the slots 324, 326, 424, 426 are shorter in size. Figure 6 In the illustrated embodiment, the slots 278 in the side rails 270 are sized higher to allow floating movement of the upper and lower opening stop spars 236 , 238 relative to the side rails 270 to allow floating movement of the panels relative to the bridge frame 208 .

[0059] In the exemplary embodiment, the bridge frame 208 is used to hold the plates 300 , 400 in the plate stack. The bridge frame 208 is used to hold the spring elements 206 . Figure 6 , a portion of the side rails 270 is shown, which support the upper opening-limiting spar 236 and the lower opening-limiting spar 238. The upper and lower opening-limiting spars 236, 238 extend through the panel stack. The upper opening-limiting spar 238 engages the upper panel 300 to limit deployment of the upper panel 300 from the lower panel 400 against the opening force of the spring element 206. The lower opening-limiting spar 238 engages the lower panel 400 to limit deployment of the lower panel 400 from the upper panel 300 against the opening force of the spring element 206. In the exemplary embodiment, the upper and lower opening-limiting spars 236, 238 are located at the seams 314, 414 to support the front and rear sections 201 relative to each other.

[0060] In the exemplary embodiment, an upper opening limiter spar 236 is located at the upper seam 314. The upper front and rear sections 310, 312 are connected together across the upper seam 314 by the upper opening limiter spar 236 to control relative movement between the upper front and rear sections 310, 312. In the exemplary embodiment, upper slots 324, 326 of the upper front and rear sections 310, 312 receive the upper opening limiter spar 236. The upper opening limiter spar 236 is positioned in the upper slots 234, 236 and received in the slot 278 in the side rail 270. The upper opening limiter spar 236 is configured to move vertically in the slot 278 to allow the upper panel 300 to compress and expand relative to the lower panel 400 and to allow the upper panel 300 to conform to the heat transfer device 106.

[0061] In the example embodiment, the lower opening limit strake 238 is located at the lower seam 414. The lower front and lower rear sections 410, 412 are connected together across the lower seam 414 by the lower opening limit strake 238 to control relative movement between the lower front and lower rear sections 410, 412. In the example embodiment, the lower channels 424, 426 of the lower front section 410 and the lower rear section 412 receive the lower opening limit strake 238. The lower opening limit strake 238 is positioned in the lower channels 424, 426 and is received in the slot 278 in the side rail 270. The lower opening limit strake 238 is configured to move vertically in the slot 278 in order to allow the lower panel 400 to compress and expand relative to the upper panel 300 and to allow the lower panel 400 to conform to the electrical components 102.

Claims

1. A thermal bridge (200), comprising: an upper bridge assembly (202, 204) comprising a plurality of upper plates arranged in an upper plate stack (302), each upper plate segmented including an upper front segment (310, 410) at a front (284) end of the upper plate and an upper back segment (312) at a back end of the upper plate, each upper plate having an upper joint between the upper front segment (310, 410) and the upper back segment (312), each upper plate having a side between the front (284) end and the back end, each upper plate having an inner end (306, 406) and an outer end (308, 408); a lower bridge assembly (202, 204) comprising a plurality of lower plates (400) arranged in a lower plate stack, each lower plate segmented including a lower front segment at a front (284) end of the lower plate and a lower back segment at a back end of the lower plate, each lower plate having a lower joint (414) between the lower front segment and the lower back segment, each lower plate having a side between the front (284) end and the back end, each lower plate having an inner end (306, 406) and an outer end (308, 408), the outer ends (308, 408) of the lower plates (400) configured to face and thermally couple to electrical components (102), the sides of some of the lower plates (400) facing the sides of some of the upper plates to thermally interface the lower plates (400) with the upper plates; a spring element positioned between the upper bridge assembly (202, 204) and the lower bridge assembly (202, 204), the spring element including an upper spring member engaging the upper plates to bias the upper plates generally away from the lower plates (400) with an opening force, the spring element including a lower spring member engaging the lower plates (400) to bias the lower plates (400) generally away from the upper plates with an opening force; and a bridge frame (208) supporting the upper plates in the upper plate stack (302) and supporting the lower plates (400) in the lower plate stack, the bridge frame (208) including upper open containment spars (236, 238) engaging the upper plates at the upper joints to limit the upper plates from unfolding from the lower plates (400) against the opening force of the spring element, the bridge frame (208) including lower open containment spars (236, 238) engaging the lower plates (400) at the lower joints (414) to limit the lower plates (400) from unfolding from the upper plates against the opening force of the spring element.

2. The thermal bridge (200) of claim 1, wherein, The upper front segments (310, 410) and the upper back segments (312) include upper slots (324, 326) receiving the upper open containment spars (236, 238), the lower front segments and the lower back segments include lower slots receiving the lower open containment spars (236, 238).

3. The thermal bridge (200) of claim 2, wherein, The upper slots (324, 326) open to the upper joints, the lower slots open to the lower joints (414). The upper slots (324, 326) open to the upper joints, the lower slots open to the lower joints (414).

4. The thermal bridge (200) of claim 2, wherein, The upper slots (324, 326) are oversized relative to the upper spar such that a gap is formed, the gap sized to allow the upper front segment (310, 410) and the upper rear segment (312) to float in the upper slots (324, 326) to allow the upper panel to compress and expand relative to the lower panel (400), the lower slots oversized relative to the lower spar such that a gap is formed, the gap sized to allow the lower front segment and the lower rear segment to float in the lower slots to allow the lower panel (400) to compress and expand relative to the upper panel.

5. The thermal bridge (200) of claim 1, wherein, The bridge frame (208) includes a first side rail at a first side of the thermal bridge (200) and a second side rail at a second side of the thermal bridge (200), the upper and lower open containment spars (236, 238) extending between the first and second side rails (260, 270).

6. The thermal bridge (200) of claim 1, wherein, The first and second side rails (260, 270) include slots that receive the upper and lower open containment spars (236, 238), the slots oversized relative to the upper and lower open containment spars (236, 238) to allow the upper and lower containment spars (236, 238) to move vertically in the slots to allow the upper and lower panels (400) to compress and expand relative to the bridge frame (208).

7. The thermal bridge (200) of claim 1, wherein, The spring elements are aligned with the upper and lower open containment slots at the upper and lower seams (414).

8. The thermal bridge (200) of claim 1, wherein, The upper open containment spars (236, 238) limit movement of the upper front segment relative to the upper rear segment, the lower open containment spars (236, 238) limit movement of the lower front segment relative to the lower rear segment.

9. The thermal bridge (200) of claim 1, wherein the bridge frame (208) includes a front rail (284), a rear rail, a first side rail extending between the front (284) rail and the rear rail, and a second side rail extending between the front (284) rail and the rear rail, the front (284) rail supporting the upper and lower front segments, the rear rail supporting the upper and lower rear segments.

10. The thermal bridge (200) of claim 9, further comprising a front spring element proximate the front (284) rail between the upper and lower front segments and a rear spring element proximate the rear rail between the upper and lower rear segments.

11. The thermal bridge (200) of claim 1, wherein the spring elements are positioned at the upper and lower seams (414), the spring elements including front spring members that engage the upper and lower front sections to bias the upper and lower front sections away from each other with the opening force, the spring elements including rear spring members that engage the upper and lower rear sections to bias the upper and lower rear sections away from each other with the opening force.

12. The thermal bridge (200) of claim 1, wherein, The upper and lower spars include vertical movement of the upper and lower panels (400) in a predetermined confined space.

13. The thermal bridge (200) of claim 1, wherein, The upper bridge assembly (202, 204) includes an upper thermal interface (108) configured to be thermally coupled to a heat transfer device (106), the upper and lower panels (400) being movable relative to each other, relative to the electrical component (102), and relative to the heat transfer device (106).

14. The thermal bridge (200) of claim 1, wherein some of the upper panels include upper overlapping regions (332) and some of the lower panels (400) include lower overlapping regions (332), the upper and lower bridge assemblies (202, 204) nesting with each other such that the upper overlapping regions (332) are in thermal contact with the lower overlapping regions (332) to thermally couple the upper and lower panels (400).

15. The thermal bridge (200) of claim 1, wherein, The upper panels include upper bridge panels and upper spacer panels between the upper bridge panels, the lower panels (400) including lower bridge panels and lower spacer panels (422) between the lower bridge panels, the upper bridge panels being aligned with the lower spacer panels (422) and the lower bridge panels being aligned with the upper spacer panels.

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