Flexure Assembly for Precise Heat Sink Alignment

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Solution Overview

Problem

Achieving precise alignment of interfacing surfaces in electronic systems is challenging due to tolerance stack-up, leading to issues with heat transfer and increased manufacturing costs, and existing solutions like rattle brackets and blind mate connectors are prone to damage and misalignment.

Innovation Solution

A flexure assembly that includes a first and second portion coupled by a flexible portion, allowing relative movement in multiple degrees of freedom, with stops to limit movement and protect against excessive deflection, facilitating precise alignment and heat transfer between components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If tight tolerances are maintained to minimize tolerance stack-up effects, then alignment precision is improved, but manufacturing costs significantly increase

Engineering Contradiction:

Improvealignment precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent introduces a flexure as an intermediary component between the cover and the heat sink. This flexure includes a first portion coupled to the cover, a second portion coupled to the heat sink, and a flexible portion that enables relative movement. By placing this flexible intermediary element in the assembly path, the system can accommodate tolerance stack-up without requiring tight tolerances on the cover and heat sink themselves, thus resolving the contradiction between alignment precision and manufacturing cost

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent changes the physical state and properties of the connection between cover and heat sink by introducing flexibility. The flexible portion of the flexure allows the system to transition from a rigid connection (requiring tight tolerances) to a compliant connection that can adapt to misalignments. This parameter change from rigidity to flexibility enables the system to tolerate larger dimensional variations while maintaining effective thermal contact

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If rattle brackets are used to allow loose connection and movement, then alignment flexibility is improved, but connection stability and reliability deteriorate

Engineering Contradiction:

Improvealignment flexibilityVSAvoidconnection stability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent applies dynamics by creating a system that transitions from static rigid connections to dynamic compliant connections. The flexure allows the heat sink to dynamically adjust its position relative to the cover within certain limits, accommodating misalignments while maintaining stable thermal contact. The flexible portion acts as a compliant element that can deflect and return, providing both movement capability and connection stability

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The flexure serves as a beforehand cushioning element that protects the connection from the harmful effects of misalignment and tolerance stack-up. By incorporating this compliant element in advance, the system is pre-prepared to absorb dimensional variations and prevent misalignment issues before they occur, rather than relying on loose rattle brackets that compromise stability

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

3Device complexity

If hard mounting is used to directly couple electronic component to cover, then assembly simplicity is improved, but damage risk and misalignment issues increase during frequent removal and reinstallation

Engineering Contradiction:

Improveassembly simplicityVSAvoidconnection durability

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent employs a flexible shell structure in the form of the flexure that couples the cover to the heat sink. This flexible element can be repeatedly deformed during assembly and disassembly operations without permanent damage or loss of functionality. The flexible portion acts as a resilient element that returns to its original position after each cycle, maintaining connection reliability even after frequent removal and reinstallation operations

Inventive Principle:

Principle #30Flexible shells and thin films

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 precise alignment of heat transfer surfaces, reduces manufacturing costs by accommodating tolerance stack-up, and prevents damage to components during assembly and disassembly, while maintaining effective thermal performance.

Implementation Method 1

a flexible portion (112) coupling the first portion (110) and the second portion (111) to one another, the flexible portion facilitating relative movement between the first and second portions in one or more degrees of freedom

Methodology Applied

Scientific EffectElasticity: Elasticity

Data Source

PatentUS10912211B2Flexure for accommodating misalignments in an assembly

Publication Date: 2021.02.02 RAYTHEON CO

AI summary

A flexure is disclosed for accommodating misalignments in an assembly. The flexure can include a first portion, a second portion, and a flexible portion coupling the first portion and the second portion to one another. The flexible portion can facilitate relative movement between the first and second portions in a plurality of degrees of freedom. The flexure can further include one or more stops operable to limit relative movement between the first and second portions in at least two of the plurality of degrees of freedom.