Modular Heat Transfer System With Adjustable Gap
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Heat-generating components in devices face challenges due to large cumulative manufacturing tolerances that result in increased thermal resistance, leading to higher operating temperatures and reduced efficiency, and existing solutions fail to maintain contact under dynamic forces like vibrations and impacts.
Innovation Solution
A modular housing system with adjustable gap sizes and a nested heat-transfer component configuration that applies a load to thermal interface materials, allowing for thinner materials and improved thermal performance while withstanding dynamic forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manufacturing tolerances are reduced to decrease gap size, then thermal resistance decreases, but manufacturing complexity and cost increase
Solution Approach 1:
The housing is designed with adjustable components that allow dynamic modification of the gap size between the heat transfer component and heat-generating components. This enables the system to adapt to manufacturing tolerances without requiring ultra-precise manufacturing, thereby reducing thermal resistance while avoiding excessive manufacturing complexity.
Solution Approach 2:
The system allows changing the physical parameters of the housing structure, specifically the gap dimensions, to optimize thermal contact. By adjusting the gap size parameter, the system achieves better thermal resistance performance while accommodating normal manufacturing tolerances.
2Manufacturing precision
If thermal interface material thickness is reduced to improve thermal performance, then thermal resistance decreases, but contact stability under dynamic forces worsens
Solution Approach 1:
The housing incorporates adjustable mechanisms that allow the gap and thermal interface material thickness to be dynamically optimized. This enables achieving thin material layers for better thermal performance while maintaining sufficient contact pressure through adjustable clamping forces to ensure stability under vibrations and impacts.
Solution Approach 2:
The design includes preliminary adjustment capabilities that allow optimizing the thermal interface before the system undergoes dynamic stress. By pre-configuring the gap and material thickness, the system prepares the thermal contact to withstand subsequent vibrations and impacts without degradation.
3Device complexity
If fixed housing configuration is used to simplify design, then device complexity decreases, but adaptability to different heat-generating components worsens
Solution Approach 1:
The housing is divided into modular segments with adjustable components, allowing independent modification of specific sections to accommodate different heat-generating components. This segmentation maintains relative design simplicity while enabling adaptability through configuration changes rather than complete redesign.
Solution Approach 2:
The adjustable housing design creates a universal platform that can accommodate multiple types of heat-generating components through configuration changes. Rather than designing separate fixed housings for each component type, the multi-functional housing adapts to serve various components, reducing overall system complexity.
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 enables the use of higher power and performing heat-generating components by reducing thermal resistance and maintaining contact under dynamic conditions, thus enhancing the operational efficiency and lifespan of heat-generating components.
Implementation Method 1
A thermal interface material may be used to improve the thermal contact between the heat-transfer component and the heat-generating component
Implementation Method 2
The liquid may absorb heat from the heat-generating component via the heat-transfer component
Data Source
AI summary
In one aspect, an apparatus comprises a first housing and a second housing. The first housing comprises a surface to receive heat from a heat-generating component. The second housing comprising a receptacle in which to receive the first housing. The first housing is to nest within the receptacle. The receptacle inhibits movement of the first housing along a first axis and facilitates movement of the first housing along a second axis. The first housing is moveable within the receptacle along the second axis. Movement of the first housing along the second axis changes a size of a gap between the surface and the heat-generating component.