Heat Spreader for Resistive Elements
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Solution Overview
Problem
Resistive elements in electronic systems face challenges with inadequate heat dissipation, particularly in small form factors, leading to potential failure due to excessive heat and changes in resistivity, especially in high-current or pulsed applications.
Innovation Solution
A heat spreader assembly is introduced, comprising a body portion over the resistive element and leg portions extending to a heat sink, with thermal interface material for efficient heat transfer, ensuring electrical insulation and enhanced heat dissipation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the physical size of electrical components is decreased to reduce system size, then the dimensions of components are reduced, but the heat dissipation capability deteriorates
Solution Approach 1:
The heat spreader extends the heat dissipation path from the traditional bottom-only contact to include top and side surfaces, effectively utilizing three-dimensional space for heat transfer. The spreader structure projects laterally from the component body, creating additional thermal contact areas with the heat sink in multiple directions.
Solution Approach 2:
The heat spreader is divided into multiple functional segments: a body portion that contacts the component housing, leg portions that extend to the heat sink, and intermediate portions that facilitate heat transfer. This segmentation allows each part to optimize its specific function while collectively solving the heat dissipation problem.
2Temperature
If resistive elements are mounted to heat sinks for heat dissipation, then heat transfer is improved, but hot spots in the center of the resistive element still occur
Solution Approach 1:
The heat spreader introduces a third dimension of heat dissipation by extending upward from the component housing to contact the resistive element's top surface and sides. This vertical extension creates additional thermal pathways that bypass the traditional bottom-only heat transfer route, effectively distributing heat away from the center hot spots.
Solution Approach 2:
The heat spreader acts as an intermediary thermal conductor between the resistive element and the heat sink. It provides a dedicated thermal pathway that intermediates the heat transfer process, allowing heat to be conducted from multiple surfaces of the resistive element through the spreader to the heat sink, thereby reducing thermal concentration.
3Temperature
If thermal contact between resistive element and heat sink is increased, then heat dissipation is improved, but electrical conduction may occur causing short circuits
Solution Approach 1:
The heat spreader serves as a thermal intermediary that is electrically isolated from the resistive element. It provides the necessary thermal contact with the heat sink while maintaining electrical insulation through its positioning and material properties, preventing short circuits while enabling efficient heat transfer.
Solution Approach 2:
The thermal management system is segmented into electrically isolated components: the resistive element, the insulating housing, the heat spreader, and the heat sink. This segmentation allows thermal contact between non-adjacent components (resistive element and heat sink) while maintaining electrical insulation through the intermediate housing and spreader structure.
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 heat spreader significantly increases heat dissipation from resistive elements, reducing temperature rise and maintaining performance across varying power levels, while maintaining mechanical integrity and compatibility with existing systems.
Implementation Method 1
leg portions that extend from the body portion and are associated with the heat sink in a thermally conductive relationship
Implementation Method 2
a thermal interface material sandwiched between the body portion and the top surface of the resistive element
Implementation Method 3
The heat spreader significantly increases heat dissipation from resistive elements
Data Source
Figure 1~2
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Figure 5~6
AI summary
A heat spreader for a resistive element is provided, the heat spreader having a body portion that is arranged over a top surface of the resistive element and electrically insulated from the resistive element. The heat spreader also includes one or more leg portion that extends from the body portion and are associated with the heat sink in a thermally conductive relationship.