Distributed Edge Clamp for Uniform Thermal Contact
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Solution Overview
Problem
In high packing density electronic systems, such as active array antennas, achieving uniform and efficient heat transfer from heat-producing circuits to cold plates is challenging, with existing methods being costly, prone to leakage, or requiring complex plumbing.
Innovation Solution
The use of elongated edge clamps with spring elements and wedging mechanisms to apply even clamping pressure between the edge of heat-producing modules and a cold plate, ensuring uniform contact and effective heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large number of heat-producing circuits are packed closely together in active array antennas, then the antenna's operational frequency and beam characteristics are achieved, but heat density increases significantly making temperature control difficult
Solution Approach 1:
The cooling system is segmented into multiple independent edge clamps distributed along the cold plate edges. Each clamp independently manages heat from specific circuit regions, allowing localized temperature control without requiring a monolithic cooling solution. This segmentation enables effective heat management in high-density configurations.
Solution Approach 2:
The invention transitions from traditional face-mounted cooling to edge-based cooling, utilizing the perimeter dimension of the cold plate. By attaching circuits to cold plate edges and using edge clamps for thermal contact, the system creates additional thermal management pathways that do not interfere with the compact circuit packing, thereby maintaining high productivity while controlling heat density.
2Reliability
If rigid clamping is used to ensure thermal contact, then heat transfer efficiency improves, but non-uniform pressure distribution causes poor contact in certain regions
Solution Approach 1:
The clamping mechanism uses spring elements that change their mechanical parameters (force, position) in response to assembly variations and thermal expansion. This dynamic parameter adjustment ensures uniform pressure distribution across the thermal interface, maintaining reliable thermal contact despite manufacturing tolerances or operational changes.
Solution Approach 2:
The edge clamp incorporates spring elements that provide dynamic, self-adjusting clamping force. Unlike rigid clamps that apply fixed pressure, the spring mechanism adapts to varying interface conditions, ensuring consistent thermal contact pressure across the entire contact surface while accommodating dimensional variations.
3Stress or pressure
If distributed spring elements are used to provide even pressure, then contact uniformity improves, but the device complexity increases
Solution Approach 1:
Multiple spring elements are merged into a single integrated edge clamp assembly that attaches to the cold plate edge. This consolidation provides distributed pressure through multiple contact points while maintaining a relatively simple overall structure, avoiding the complexity of fully distributed independent spring mechanisms.
Solution Approach 2:
The edge clamp assembly serves multiple functions: it provides mechanical support for the circuits, ensures thermal contact through distributed spring pressure, and accommodates thermal expansion. This multi-functionality reduces the need for separate components, thereby limiting the increase in device complexity while achieving uniform pressure distribution.
4Loss of energy
If conventional cooling methods are used, then heat removal is achieved, but the systems become costly or require complex plumbing
Solution Approach 1:
The invention extracts the thermal management function from the main body of the cold plate and relocates it to the edges. By using edge clamps that attach to the perimeter, the system simplifies the cooling architecture, eliminating the need for complex internal plumbing or distributed cooling components within the cold plate volume, thereby reducing overall system complexity while maintaining effective heat removal.
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
This solution provides consistent and efficient heat transfer by distributing pressure evenly across the edge of the modules, improving thermal contact with the cold plate and reducing the risk of leakage or complexity in plumbing.
Implementation Method 1
an elongated spring element including first and second generally mutually parallel spring plates
Implementation Method 2
An elongated wedging element including a plurality of wedges along its length is fixed against motion in directions other than the direction of elongation of the wedging element, and is forced to move axially in the direction of elongation
Implementation Method 3
providing such even pressure between a heat-generating item and a heat sink or cold plate
Data Source
AI summary
An arrangement for clamping a flat plate to a flat surface includes juxtaposing the plate to the flat surface. An axially-movable wedging element defining a surface fitted with wedges is fixed against motion in other than a direction of elongation, and is forced to move in the direction of elongation. The wedges are forced against a first spring beam to impart forces thereto. The forces are coupled from the first spring beam to a second spring beam by intermediary supports. The second spring beam bears against a surface of the flat plate to force the plate against the flat surface.