Injection Assembly for Thermal Interface Material Coating
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Solution Overview
Problem
Conventional methods for applying thermal interface materials (TIMs) to heating modules in controllers are time-consuming and risk damaging the chips or circuit boards due to pressure application.
Innovation Solution
An injection assembly that simultaneously injects and applies an injection material with low viscosity into multiple coating portions, using a cover part with injection holes and a nozzle unit with pressure sensors to control injection speed and prevent damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the sandwich method is used to coat TIM on heating elements before assembly, then the TIM can be applied to multiple chips, but the processing time increases and the chips may be damaged due to pressure
Solution Approach 1:
The injection holes are pre-formed in the cover part at positions corresponding to the heating elements before assembly. This preliminary preparation allows the TIM to be injected directly into the assembled structure, eliminating the need for separate pre-coating steps and reducing the overall process cycle time.
Solution Approach 2:
The patent uses an injection system that utilizes pressure differential (pneumatic/hydraulic principle) to push the TIM through the injection holes from the cover part into the heating element gaps. This automated injection method replaces manual coating processes, significantly reducing processing time while applying controlled pressure that prevents chip damage.
2Quantity of substance
If the sandwich method is used to coat TIM on heating elements, then multiple chips can be coated, but the chips and circuit boards may be damaged due to pressure application
Solution Approach 1:
The injection system uses controlled pressure differential to push TIM through injection holes. The pressure is applied gradually and controlled by the injection mechanism, preventing sudden or excessive pressure spikes that could damage the chips or circuit boards, while still achieving complete TIM filling of the heating element gaps.
Solution Approach 2:
The injection holes act as intermediaries that guide the TIM flow directly to the heating element gaps. This intermediary structure allows the TIM to be delivered precisely where needed without requiring direct pressure application to the chip surfaces, thereby preventing damage while ensuring complete coating.
3Reliability
If conventional coating methods are used for multiple chips, then the TIM can be applied to each chip, but the number of coating operations increases the process cycle
Solution Approach 1:
The patent merges the TIM injection function with the existing assembly structure by integrating injection holes into the cover part. This allows multiple heating elements to be coated simultaneously through a single injection operation, combining what would otherwise be multiple separate coating operations into one unified process, thereby reducing the overall process cycle while maintaining coating completeness.
Solution Approach 2:
The injection system is designed to serve multiple heating elements simultaneously through a single operational cycle. The injection holes are positioned to correspond with multiple heating element locations, allowing the same injection mechanism to coat multiple chips in sequence or parallel, thereby improving productivity without compromising coating reliability.
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 solution significantly reduces processing time, prevents damage to heating elements and circuit boards, and ensures complete coating of the surface with the injection material, enhancing heat transfer efficiency.
Implementation Method 1
a nozzle unit (200) including a plurality of nozzles (210) to simultaneously inject an injection material into the plurality of injection holes (120)
Implementation Method 2
using the injection material with a relatively low viscosity to prevent generation of an air layer so as to completely coat a coating surface with the injection material
Implementation Method 3
The TIM decreases thermal resistance between a heating element and a heat sink so that heat is smoothly transferred from the heating element to the heat sink
Data Source
AI summary
An injection assembly including a cover part which covers an upper surface of a controller and in which a plurality of injection holes are formed to correspond to positions of a plurality of heating elements and a nozzle unit including a plurality of nozzles to simultaneously inject an injection material into the plurality of injection holes, wherein a pressure sensor is disposed in each of the plurality of nozzles to measure an internal pressure of the nozzle and to control an injection speed based on the measured internal pressure.