Phase Change Thermal Connector for Tolerance Management
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Solution Overview
Problem
Existing thermal connectors between heat generating devices and heat sinks have low thermal conductivities and are limited in accommodating varying tolerances between multiple components and a heat sink, making it difficult to effectively transfer heat and assemble devices.
Innovation Solution
A thermal connector comprising a heat spreader, a spring, a flexible membrane, and a phase change material that expands or contracts to accommodate tolerance variations, ensuring effective heat transfer between heat generating components and heat sinks, with the spring and phase change material working together to maintain contact and seal the interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If thermal pads with high conductivity (17 W/mK) are used, then thermal conductivity is improved, but the component can only be compressed to 10%-20% or the component will be damaged, limiting the size of the starting gap and making assembly more difficult
Solution Approach 1:
The patent uses a phase change material that changes from solid to liquid at a specific temperature (e.g., 100°C). During assembly at room temperature, the material remains solid and can be compressed to fill gaps of any size without damaging components. When heated during operation, it melts and flows to ensure complete contact between the heat spreader and heat sink, providing both high thermal conductivity and ease of assembly.
Solution Approach 2:
The thermal connector utilizes a phase change material that transitions from solid to liquid at an predetermined temperature. This phase transition allows the material to adapt its physical state: solid during assembly for mechanical support and gap filling, and liquid during operation for optimal thermal contact and conformability to surfaces.
2Adaptability or versatility
If compressible and expandable thermal connectors are used to accommodate several different tolerances, then adaptability is improved, but thermal conductivity remains low (3-17 W/mK)
Solution Approach 1:
The patent employs a phase change material that transitions from solid to liquid at an predetermined temperature, fundamentally changing its physical properties. In solid state during assembly, it provides mechanical compliance to accommodate various tolerances. In liquid state during operation, it achieves high thermal conductivity for efficient heat transfer, thus resolving the contradiction between adaptability and thermal conductivity.
3Adaptability or versatility
If the starting gap between the component and heat sink is large, then tolerance accommodation is improved, but compression of thermal pads to 10%-20% is required which limits assembly options
Solution Approach 1:
The phase change material remains solid during assembly, allowing the starting gap to be of any size without requiring compression of the thermal connector itself. The material is contained within a flexible membrane that can expand to fill the gap. When heated during operation, the material melts and flows to ensure complete contact, eliminating the need for compression during assembly and simplifying the assembly process.
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 enhances thermal conductivity and adaptability, allowing for efficient heat transfer across a range of tolerances, improving device assembly and performance by using a phase change material with high thermal conductivity and a flexible membrane to maintain contact and accommodate varying gaps.
Implementation Method 1
a phase change material that fills the recess, wherein the flexible membrane contains the phase change material and allows it to contract or expand in response to the movement of the heat spreader towards or away from the heat sink
Implementation Method 2
a spring configured to sit between the heat spreader and with the heat sink and bias the heat spreader towards and away from the heat sink
Implementation Method 3
transfer heat from the component to the heat sink
Data Source
AI summary
A thermal connector configured to be placed within a recess of a heat sink between the heat sink and a heat generating component and transfer heat from the component to the heat sink, including a heat spreader configured to fit within the recess of the heat sink, a spring configured to sit between the heat spreader and with the heat sink and bias the heat spreader towards and away from the heat sink, a flexible membrane attached to the heat sink and the heat spreader and seal off the recess, and a phase change material that fills the recess, wherein the flexible membrane contains the phase change material and allows it to contract or expand in response to the movement of the heat spreader towards or away from the heat sink.