Adaptive Composite Structure for CTE-Matched Thermal Regulation
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Solution Overview
Problem
High-powered electronic devices face challenges in thermal management due to coefficient of thermal expansion (CTE) mismatches and inefficient heat transfer mechanisms, which can lead to reliability issues under varying temperature conditions.
Innovation Solution
An adaptive structure is formed by infiltrating different materials into an initial structure with voids, creating a metal-matrix composite that matches the CTE of heat-generating components and provides an efficient path for thermal energy removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a single material is used for the support structure, then the manufacturing process is simple, but the coefficient of thermal expansion cannot match both the heat-generating components and the mating surfaces
Solution Approach 1:
The patent applies composite materials by creating a support structure with a gradient composition of first and second materials. The first material has a first coefficient of thermal expansion that matches the heat-generating components, while the second material has a second coefficient of thermal expansion that matches the mating surfaces. This gradient composite structure enables CTE matching at both interfaces simultaneously, resolving the contradiction between reliability and material complexity.
Solution Approach 2:
The patent implements local quality by varying the material composition at different locations within the support structure. The gradient structure provides different local CTE properties: regions closer to the heat-generating components have higher concentration of the first material for CTE matching, while regions closer to the mating surfaces have higher concentration of the second material. This spatial variation in material properties resolves the contradiction by providing locally optimized CTE matching.
2Temperature
If thermal management is prioritized, then heat transfer efficiency improves, but dimensional stability under temperature variation deteriorates due to CTE mismatch
Solution Approach 1:
The gradient composite structure simultaneously addresses thermal management and dimensional stability. The first material in the gradient provides efficient thermal conduction pathways from the heat-generating components, while the second material provides CTE matching with mating surfaces for dimensional stability. The gradual transition between materials ensures both heat transfer efficiency and thermal expansion compatibility across the temperature range.
Solution Approach 2:
The local quality principle enables different regions of the support structure to fulfill different functions: regions with higher first material concentration optimize heat transfer from components, while regions with higher second material concentration maintain dimensional stability at mating surfaces. This spatial functional differentiation resolves the contradiction between temperature management and compositional stability.
3Reliability
If CTE matching is optimized, then reliability under thermal cycling improves, but thermal conduction efficiency may be compromised
Solution Approach 1:
The gradient composite material structure resolves the contradiction by distributing thermal management functions across the material gradient. The first material provides CTE matching with heat-generating components for reliable thermal cycling, while the second material provides CTE matching with mating surfaces. The gradual transition maintains continuous thermal pathways, ensuring efficient heat conduction without compromising reliability under thermal cycling.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The adaptive structure effectively addresses CTE mismatches and enhances thermal management by providing custom-tuned mechanical properties and efficient heat transfer, ensuring dimensional stability and reliability across a range of temperatures.
Implementation Method 1
infiltrating one or more second materials into the initial structure
Implementation Method 2
creating a metal-matrix composite that matches the CTE of heat-generating components
Implementation Method 3
provides an efficient path for thermal energy removal
Implementation Method 4
A combination of the first and second materials provides a coefficient of thermal expansion in a portion of the finished structure that substantially matches a coefficient of thermal expansion of the one or more heat-generating components
Data Source
AI summary
A method includes forming an initial structure having voids, where the initial structure includes one or more first materials. The method also includes infiltrating one or more second materials into the initial structure, where the one or more second materials are different from the one or more first materials. The method further includes forming a finished structure configured to receive and support one or more heat-generating components. A combination of the first and second materials provides a coefficient of thermal expansion in a portion of the finished structure that substantially matches a coefficient of thermal expansion of the one or more heat-generating components. The finished structure is configured to provide a path to remove thermal energy from the one or more heat-generating components.