Flexible Heat Exchange Assembly for Electrical Devices
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Solution Overview
Problem
Known electrical devices face limitations in heat transfer efficiency due to the use of solid heat spreader bars, which result in increased thermal resistance and operational temperature, leading to reduced reliability and potential component failure.
Innovation Solution
A flexible heat exchange assembly with a bending capability is introduced, featuring an evaporator section, condenser section, and transport section that channels a working fluid between the electrical component and heat sink, reducing the distance heat must travel and allowing for thinner, more efficient thermal interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid heat spreader bar is used to transfer heat from the electrical component to the heat sink, then the heat transfer path is established, but the thermal resistance increases and heat transfer efficiency decreases
Solution Approach 1:
The patent replaces the solid heat spreader bar with a flexible heat exchange assembly that uses a working fluid (liquid or gas) to transfer heat. The fluid circulates through channels in the flexible assembly, absorbing heat from the electrical component and transporting it to the heat sink, thereby reducing thermal resistance and improving heat transfer efficiency compared to solid conduction alone
Solution Approach 2:
The flexible heat exchange assembly utilizes phase transitions of the working fluid (evaporation and condensation) to enhance heat transfer. The fluid evaporates at the evaporator section absorbing heat from the electrical component, and condenses at the condenser section releasing heat to the heat sink, providing efficient heat transfer with lower thermal resistance
2Adaptability or versatility
If thick, compliant thermal interface materials are used to accommodate dimensional tolerances, then assembly flexibility is improved, but thermal resistance increases and heat transfer efficiency decreases
Solution Approach 1:
The patent employs a flexible heat exchange assembly that can dynamically bend and deform to accommodate dimensional tolerances and non-planarity between components. This flexible structure maintains good thermal contact without requiring thick interface materials, as the flexibility itself compensates for gaps and misalignments while preserving heat transfer efficiency
Solution Approach 2:
The heat exchange assembly is constructed as a flexible structure with thin walls that can conform to the surfaces of the electrical component and heat sink. This flexible thin-walled structure accommodates dimensional variations and non-planarity while maintaining effective thermal contact, eliminating the need for thick, high-compliance thermal interface materials that would increase thermal resistance
3Length of stationary object
If the distance heat must travel from the electrical component to the heat sink is increased, then the heat transfer path is extended, but the heat transfer capacity is limited
Solution Approach 1:
The flexible heat exchange assembly uses a working fluid circulating through internal channels to transfer heat over extended distances. The fluid continuously circulates from the evaporator section near the electrical component through the transport section to the condenser section at the heat sink, enabling efficient heat transfer over longer path lengths that would be ineffective with solid conduction alone
Solution Approach 2:
The phase transition mechanism (evaporation at the evaporator, condensation at the condenser) provides intense heat transfer at the endpoints of the heat exchange assembly. This allows the system to effectively manage heat over extended distances by concentrating phase change heat transfer at the component interfaces, maintaining high heat transfer capacity despite increased path length
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 flexible heat exchange assembly enhances heat transfer efficiency, reduces operational temperatures, and decreases maintenance costs by accommodating dimensional tolerances and increasing the reliability of electrical components.
Implementation Method 1
an evaporator section, a condenser section, and a transport section extending between the evaporator section and the condenser section for channeling a working fluid between the evaporator section and the condenser section
Implementation Method 2
a condenser section coupled to the heat sink... transferring heat from the component to the working fluid, and transferring heat from the working fluid to the heat sink
Data Source
AI summary
An electrical device is described herein. The electrical device includes a housing that includes an inner surface that defines a cavity, a heat sink that is coupled to the housing and oriented along a first plane, and at least one electrical component positioned within the housing cavity and oriented along a second plane that is different than the first plane. A heat exchange assembly is coupled to the electrical component and the heat sink for adjusting a temperature of the electrical component. The heat exchange assembly includes an evaporator section, a condenser section, and a transport section extending between the evaporator section and the condenser section for channeling a working fluid between the evaporator section and the condenser section. The heat exchange assembly is configured to bend along at least one bending axis oriented with respect to the transport section.