Flexible Thermal Bridge Extensions for PBA Module Chassis Interface
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Solution Overview
Problem
Existing PBA module mounting and fastening systems, such as wedge clamp assemblies, create thermal bottlenecks due to small contact areas, leading to uneven thermal resistance and mechanical stress, particularly when PBA modules are clamped against one chassis channel wall, causing alignment and mating issues.
Innovation Solution
A PBA module design featuring thermal bridge stiffeners with flexible extensions that allow for better mechanical fit and thermal conduction by moving laterally to increase contact area when pressure is applied, reducing thermal resistance and eliminating mechanical stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wedge clamp assembly is used to fasten PBA module to chassis channel, then mechanical locking and heat sinking are provided, but thermal resistance increases due to small contact areas creating thermal bottlenecks
Solution Approach 1:
The thermal bridge structure is segmented into multiple components: a first thermal bridge structure contacting the first chassis channel wall, a second thermal bridge structure contacting the second chassis channel wall, and a PBA module sandwiched between them. This segmentation allows each component to be optimized independently for its specific function.
Solution Approach 2:
The PBA module itself serves as an intermediary thermal conduction path between the two chassis channel walls. By sandwiching the PBA module between the thermal bridge structures, heat can be conducted through the PBA module's substrate and components, providing a low thermal resistance path that eliminates the thermal bottleneck issue.
2Stability of the object's composition
If PBA module is clamped against one chassis channel wall, then mechanical stability is achieved, but alignment and mating issues occur due to mechanical stress
Solution Approach 1:
The thermal bridge structures are positioned asymmetrically relative to the PBA module's centerline, with the first thermal bridge structure contacting the first chassis channel wall and the second thermal bridge structure contacting the second chassis channel wall. This asymmetric configuration allows the PBA module to be centered in the chassis channel while maintaining stable mechanical contact points.
Solution Approach 2:
The thermal bridge structures provide equipotential mechanical support by contacting both chassis channel walls, distributing mechanical stresses evenly across the PBA module. This prevents localized stress concentrations that would cause alignment and mating issues.
3Adaptability or versatility
If thermal bridge external skin is displaced from PB surface to provide component clearance, then component clearance is achieved, but contact area with chassis channel wall is reduced
Solution Approach 1:
The thermal bridge external skin has different properties at different locations: at the chassis channel interface, it maintains direct contact with the chassis channel wall to maximize heat conduction area, while at the PBA interface, it is displaced to provide necessary component clearance. This local differentiation of properties allows simultaneous optimization of both contact area and clearance.
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 thermal bridge extensions ensure improved thermal conduction and mechanical stability by increasing contact area between the PBA module and chassis channels, reducing thermal bottlenecks and alignment issues, while maintaining ease of insertion and extraction.
Implementation Method 1
The first extension is made of a flexible material and is affixed to the first side portion of the first thermal bridge stiffener. The second extension is made of a flexible material and is affixed to the second side portion of the second thermal bridge stiffener.
Implementation Method 2
thermal conduction between the PBA module and the one or more chassis channels
Data Source
AI summary
A module for use with an expandable wedge clamp assembly in a chassis channel is provided. The module comprises a first side, a second side, a first extension attached to the first side, and a second extension attached to the second side. The first extension and the second extension are flexible. When the wedge clamp assembly is expanded, the first extension and the second extension flex from a first position to a second position. When the wedge clamp is returned from the expanded position to a relaxed position, the first extension and the second extension return from the second position to the first position.