Flexible Sensor Interconnect for Thermal Expansion Mismatch

Solution Overview

Problem

The relative displacement between the flow channel component and the box body due to differing expansion coefficients leads to disconnection issues in the electrical connection between the sensor and control component in thermal management assemblies.

Innovation Solution

Incorporating a flexible connecting component, such as a flexible circuit board, that is deformable to accommodate differential expansion, reducing stress and maintaining reliable connections between the sensor and control component.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If different materials are used for the flow channel component and the box body to achieve desired functional properties, then the thermal management assembly can be optimized for performance, but the difference in expansion coefficients causes relative displacement leading to electrical connection failure

Engineering Contradiction:
Core Design Contradiction:
Adaptability or versatilityVSReliability

Solution Approach 1:

The patent employs a flexible connecting component (flexible circuit board) to replace rigid electrical connections. This flexible component can deform to accommodate the relative displacement caused by differential thermal expansion between the flow channel component and box body, thereby maintaining reliable electrical connections while allowing the use of different materials for optimal thermal management performance

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The patent changes the physical state and mechanical properties of the connecting component by selecting a flexible material with appropriate elastic modulus and thermal expansion characteristics. This allows the connection to dynamically adapt to temperature changes and dimensional variations, preventing connection failure while maintaining electrical conductivity

Inventive Principle:
Principle #35Parameter changes

2Reliability

If rigid electrical connections are used between the sensor and control component, then the electrical connection is stable under normal conditions, but the connection fails due to stress concentration when thermal expansion differences cause relative displacement

Engineering Contradiction:
Core Design Contradiction:
ReliabilityVSStrength

Solution Approach 1:

The flexible connecting component replaces rigid electrical connectors, providing both electrical conductivity and mechanical flexibility. This allows the connection to absorb stress from thermal expansion differences without concentrating forces that would lead to failure, maintaining both stability and stress resistance

Inventive Principle:
Principle #30Flexible shells and thin films

Solution Approach 2:

The flexible connecting component inherently provides stress cushioning before failure can occur. Its elastic properties allow it to deform and absorb the stresses generated by differential thermal expansion, preventing stress concentration and connection failure before they can happen

Inventive Principle:
Principle #11Beforehand cushioning (Prior cushioning)

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 connecting component stabilizes connections by minimizing relative displacement and stress, ensuring reliable electrical connections despite thermal expansion differences, facilitating miniaturization and integration of the thermal management assembly.

Implementation Method 1

The materials of the flow channel component and the box body are usually different. The difference between the expansion degree of the flow channel component and the expansion degree of the box body causes relative displacement between the flow channel component and the box body

Methodology Applied
Scientific EffectThermal expansion: Thermal Expansion

Implementation Method 2

the flexible connecting component is deformable, which reduces the relative displacement between the flow channel component and the box body due to different degrees of expansion

Methodology Applied
Scientific EffectElasticity: Elasticity

Data Source

PatentUS20260009608A1Thermal management assembly with flexible connecting component
Publication Date: 2026.01.08
  • US20260009608A1 patent drawing
  • US20260009608A1 patent drawing
  • US20260009608A1 patent drawing

AI summary

A thermal management assembly includes a flow channel component, a box body, a sensor, a control component and a flexible connecting component. The flow channel component has a first expansion coefficient. The box body has a second expansion coefficient different from the first expansion coefficient. The sensor and the flow channel component are fixedly connected. The control component and the box body are fixedly connected. One end of the flexible connecting component is electrically connected to the sensor, and another end of the flexible connecting component is electrically connected to the control component. The flexible connecting component disclosed in the present disclosure is deformable, thereby reducing a relative displacement between the flow channel component and the box body due to different degrees of expansion when the thermal management assembly operates.