Segmented Thermal Bridge Plates for Conformable Heat Transfer
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Solution Overview
Problem
Existing thermal management systems face inefficiencies in heat dissipation due to limited thermal interface areas and variations in surface flatness, leading to degraded performance and potential damage of electrical components.
Innovation Solution
A thermal bridge assembly comprising segmented upper and lower plate stacks with spring elements and a bridge frame, allowing for conformable thermal coupling between electrical components and heat transfer devices, enhancing thermal energy transfer through compressible and conformable segments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional heat sinks are used with fixed thermal interfaces, then the structure is simple, but thermal energy transfer efficiency is reduced due to limited interface area and surface flatness variations
Solution Approach 1:
The thermal bridge assembly is divided into multiple segmented plates (first set of plates and second set of plates) that can independently conform to surface variations. Each plate segment can adapt to local surface irregularities, maximizing thermal interface area and improving heat transfer efficiency while maintaining manageable structural complexity through modular design
Solution Approach 2:
The segmented plates are designed to be movable relative to each other, allowing the thermal bridge assembly to dynamically adapt its configuration to match the contours of the electrical component and heat transfer device surfaces. This dynamic adjustment capability enables optimal thermal contact without requiring a completely complex rigid structure
2Loss of energy
If rigid thermal coupling is used, then structural stability is maintained, but thermal contact efficiency decreases due to inability to conform to surface variations
Solution Approach 1:
The segmented plates are designed to be movable relative to each other, allowing the thermal bridge assembly to dynamically adapt its configuration to match the contours of the electrical component and heat transfer device surfaces. This dynamic adjustment capability enables optimal thermal contact without requiring a completely complex rigid structure
Solution Approach 2:
The patent combines rigid plate structures with flexible segmentation and spring elements to create a hybrid system that achieves both structural stability and conformability. The plates maintain structural integrity while their segmented arrangement and spring mechanisms enable adaptation to surface variations, merging the benefits of rigid and flexible designs
3Loss of energy
If spring elements are added to provide conformable coupling, then thermal contact is improved, but the risk of plates spreading apart increases
Solution Approach 1:
The thermal bridge assembly is divided into multiple segmented plates (first set of plates and second set of plates) that can independently conform to surface variations. Each plate segment can adapt to local surface irregularities, maximizing thermal interface area and improving heat transfer efficiency while maintaining manageable structural complexity through modular design
Solution Approach 2:
Spring elements are introduced as intermediary components between the plate segments to provide controlled elastic forces. These springs act as mediators that allow the plates to conform to surface variations while preventing excessive spreading, maintaining both thermal contact and structural integrity through controlled elasticity
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 thermal bridge assembly improves thermal energy transfer efficiency by conforming to the shapes of electrical components and heat transfer devices, maintaining effective thermal contact and reducing the risk of component degradation.
Implementation Method 1
The spring element includes an upper spring member engaging the upper plates to bias the upper plates with an opening force generally away from the lower plates. The spring element includes a lower spring member engaging the lower plates to bias the lower plates with an opening force generally away from the upper plates.
Implementation Method 2
The outer ends of the lower plates configured to face and thermally couple to an electrical component. The sides of some of the lower plates face the sides of some of the upper plates to thermally interface the lower plates with the upper plates.
Data Source
AI summary
A thermal bridge includes an upper bridge assembly including upper plates and a lower bridge assembly including lower plates. The upper and lower plates are segmented including forward segments and rearward segments meeting at a seam. The ends of the lower plates face and thermally couple to an electrical component. The sides of some of the lower plates face the sides of some of the upper plates to thermally interface the lower plates with the upper plates. The thermal bridge includes a spring element positioned between the upper bridge assembly and the lower bridge assembly. The thermal bridge includes a bridge frame supporting the upper plates and the lower plates. The bridge frame includes open limit spars engaging the plates at the seam to limit spreading apart of the plates from each other against the opening forces of the spring element.