Optical Module Housing Thermal Conductivity Segmentation
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Solution Overview
Problem
The existing optical modules face challenges in efficiently radiating heat due to the limitations of their box-shaped cases, which are often made of materials with lower thermal conductivity, especially as the heat generation increases with higher functional density.
Innovation Solution
The optical module design incorporates a housing with a first case made of a material with higher thermal conductivity, such as copper, and a second case made of a lower-cost material like a zinc alloy, where the first case is in physical contact with heat-radiation sheets and a heat sink, enhancing heat transfer and radiation performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the box-shaped case is made of metal alloy (zinc or aluminum) with integral die-casting for processability and low cost, then manufacturing cost and ease of manufacture are improved, but thermal conductivity and heat radiation performance deteriorate
Solution Approach 1:
The case is divided into two separate cases: a first case made of high thermal conductivity metal (such as copper) and a second case made of cost-effective metal alloy (such as zinc or aluminum alloy). The first case is specifically designed to contact heat-generating components, while the second case provides structural support and cost efficiency. This segmentation allows each case to fulfill its specific function optimally.
Solution Approach 2:
The first case made of high thermal conductivity material is strategically positioned to contact heat-generating components such as optical sub-assemblies and control circuits. This local quality approach ensures that the region requiring heat dissipation uses the appropriate material, while other regions use cost-effective materials.
2Adaptability or versatility
If high-density mounting is performed to achieve greater function, then functionality and integration are improved, but heat generation increases and heat radiation performance deteriorates
Solution Approach 1:
By segmenting the case into thermal management and structural functions, the patent enables effective heat dissipation even when high-density mounting increases overall heat generation. The first case made of high thermal conductivity material is specifically designed to handle the increased heat load from densely mounted components.
3Device complexity
If a single material is used for both cases to simplify structure, then device complexity is reduced, but heat radiation performance and cost-effectiveness deteriorate
Solution Approach 1:
The case is segmented into two separate cases with different materials optimized for different functions. The first case handles thermal management while the second case provides structural support, achieving better overall performance than a single-material design.
Solution Approach 2:
The patent uses a composite structure combining two different metal materials (high thermal conductivity metal and metal alloy) in a multi-case configuration. This composite approach allows the system to benefit from both high thermal conductivity and cost-effectiveness.
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
This configuration significantly improves heat radiation efficiency, allowing more heat to be dissipated from the optical module to the heat sink, even under high-density operational conditions, while maintaining cost-effectiveness.
Implementation Method 1
a material of the first case has a thermal conductivity higher than a material of the second case
Data Source
AI summary
An optical module includes at least one optical sub-assembly; at least one control circuit configured to control the at least one optical sub-assembly; and a housing including a first case and a second case, wherein the optical module is configured to be plugged in and unplugged from an optical transmission equipment including a heat sink provided at a joining portion with the first case, wherein, through fitting of the first case and the second case, the housing accommodates the at least one optical sub-assembly and the at least one control circuit inside the housing, and wherein a material of the first case has a thermal conductivity higher than a material of the second case.