Circuit Board Assembly With Movable Connectors For Heat Sink
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Solution Overview
Problem
In radar systems with limited space, such as aircraft noses, existing circuit board assemblies face challenges in aligning and connecting electrical cables due to the wide spacing of antenna array elements, leading to difficulties in folding cables for retention within heat sinks and ensuring manual access to all connectors.
Innovation Solution
A compact circuit board assembly with a heat sink sandwiched between two boards, featuring flexible electrical cables with slits and board connectors that can move relative to the heat sink, allowing self-alignment and blind-mating without external connectors, and an internal coolant pathway for enhanced cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical cables are made long enough to reach all connectors on widely spaced antenna array elements, then electrical connection is achieved, but cable folding and retention within the heat sink becomes difficult
Solution Approach 1:
The patent applies the dynamics principle by making the cable connector movable relative to the heat sink rather than fixed. This allows the connector to dynamically adjust its position during assembly to accommodate misalignment, and during operation to accommodate thermal expansion and contraction. The movable connector is achieved through a retention mechanism that allows limited movement in specific directions while maintaining electrical connection.
Solution Approach 2:
The patent applies parameter changes by allowing the cable connector to change its positional parameters (x, y, z coordinates) within a certain range. This positional flexibility enables the connector to adapt to alignment variations without requiring precise manual positioning, thereby simplifying the assembly process and improving reliability.
2Device complexity
If shorter electrical cables are used to facilitate folding and retention within the heat sink, then cable retention becomes easier, but manual access to all connectors is not provided
Solution Approach 1:
The movable connector design enables shorter cables to be used while maintaining ease of operation. The connector's ability to move allows it to reach all necessary connection points on the circuit board without requiring the cable to be excessively long, thus facilitating both retention within the heat sink and manual access during assembly.
Solution Approach 2:
The self-aligning feature of the movable connector provides self-service during assembly. The connector automatically positions itself relative to the circuit board contacts through its movement capability, reducing the need for precise manual alignment and making the assembly process easier despite using shorter cables.
3Manufacturing precision
If connectors are rigidly fixed to the heat sink, then alignment precision is improved, but flexibility and adaptability to misalignment are reduced
Solution Approach 1:
The patent implements dynamics by transitioning from a rigid fixed connector to a movable connector that can adapt its position. This dynamic capability allows the system to maintain manufacturing precision for the heat sink structure while accommodating alignment tolerances through the connector's movement, thereby improving adaptability without sacrificing overall alignment quality.
Solution Approach 2:
The movable connector design provides beforehand cushioning against alignment misalignment. By built-in movement capability, the system pre-compensates for potential alignment issues that may arise during assembly or operation, cushioning against the harmful effects of misalignment before they can cause connection failures.
4Reliability
If multiple separate connectors are used for each antenna array element, then electrical connection reliability is improved, but assembly complexity and time increase
Solution Approach 1:
The patent applies merging by combining multiple electrical connection functions into a single movable connector assembly. Rather than handling multiple separate connectors individually, the movable connector integrates the connection functions, allowing all electrical connections to be established simultaneously in one assembly operation, thereby improving productivity while maintaining reliability.
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
Enables efficient electrical connection and heat dissipation in compact radar systems, facilitating alignment and connection of cables within the heat sink while maintaining flexibility and cooling efficiency, suitable for space-constrained applications.
Implementation Method 1
a heat sink arranged to sink heat away from the two circuit boards; the heat sink lying between and in contact with both of the two circuit boards
Implementation Method 2
The heat sink comprises a closed channel for the passage of a coolant to provide improved cooling function
Data Source
AI summary
A radar system includes two circuit boards, a first carries an array of antenna elements and the second carries power circuitry to power the circuitry of the first board. To provide adequate cooling whilst minimising the size of the system the two circuit boards are mounted in a sandwich arrangement on opposite sides of a heat sink. Data and power connections between the two boards are provided by a plurality of electrical cables that extend through apertures in the heat sink.