Sealable multi-surface electronics thermal conduction package

An electronics thermal conduction package is provided. The package may include a housing and an interior space, or envelope, configured to receive a printed circuit board assembly (“PCBA”) with one or more microprocessors or other heat generating elements. The package can be elastically deformed to open a dimension of the envelope, or receiving cavity, such that a complete PCBA can be inserted inside the interior space of the package. Once inserted, the package may be returned to its undeformed, or substantially undeformed, state such that surfaces in the interior space of the package contact one or more of the heat generating elements on the PCBA creating a conductive thermal path from the heat generating elements to the housing of the package.

FIELD

The present disclosure is generally directed to electronics packaging, in particular, toward environmentally-sealed thermally-controlled packages for electronic component assemblies.

BACKGROUND

Most electronic devices generate heat while in use. This heat is typically generated by the flow of electric current through one or more resistive elements and/or components in the electronic device. When the heat generated by these elements and/or components is not efficiently removed, the temperatures of an electronic device can exceed a normal operating range. Operating electronics at temperatures outside of the normal operating range, even periodically, can cause premature failures and result in shorter component life spans.

The efficient thermal management of electronic components and devices generally requires one or more active and/or passive cooling elements. For example, typical microprocessors may generate heat that can be removed or dissipated via an attached heat sink and/or some other cooling element/system, such as a fan, directed cooled air, fluid cooling, etc. In this example, the heat generated may be routed to, and/or dissipated, into an environment immediately surrounding the microprocessors.

However, the options for removing heat from an electronic device within a sealed environment (e.g., hermetic package, pseudo-hermetic package, sealed enclosure, etc.) may be limited to those approaches employing costly, sizable, and/or complex cooling systems.

DETAILED DESCRIPTION

Embodiments of the present disclosure will be described in connection with electronics packaging, and in some embodiments, the construction, structure, and arrangement of elements making up a sealable multi-surface electronics thermal conduction package.

In some embodiments, the present disclosure describes a compact thermal conduction package configured to conductively cool multiple surfaces of electronics sealed inside a package. The package may include a housing and an interior space, or envelope, configured to receive a printed circuit board assembly (“PCBA”) with one or more microprocessors and/or other heat generating elements. In one embodiment, the PCBA may include microprocessors disposed on opposing planar faces of the printed circuit board (PCB) or substrate. In general, the present disclosure provides a package that can be elastically deformed to open a dimension of the envelope, or receiving cavity, such that a complete PCBA can be inserted inside the interior space of the package. Once inserted, the package may be returned to its undeformed, or substantially undeformed, state such that surfaces in the interior space of the package contact one or more of the heat generating elements on the PCBA creating a conductive thermal path from the heat generating elements to the housing of the package.

In some embodiments, the package may include an extruded shape or housing. The housing may include a number of cooling fins, or heat sink surfaces, disposed on an outside of the housing, at least one pressure contact area, and an interior space/receiving cavity and/or PCB envelope configured to receive a PCBA and/or other electronics.

As described herein, the housing of the package may include a weakened, controlled cross-sectional area, or flexure, configured to elastically bend, or deform, when a force is applied to one or more of the ends having the pressure contact area. For example, as force, F is applied to the ends of the package, an internal height dimension, HC, may be increased from a first height dimension, HC, to a second increased height dimension, (HC+Y), where Y is a non-zero distance, creating an expanded space to receive a PCBA and/or other electronics.

Although described herein as compressive, or squeezing, forces, it should be appreciated, that only one force, F, need be applied to an end of the package while the opposing end is held in place. This containment of the package while a force, F, is applied effectively provides an equal and opposing force against the opposing end of the package. Further, the flexure area(s) of the package may be designed to control the application of force such that the envelope is opened outwardly from the center and not collapsed toward the interior space of the package.

Once compressed, and while maintaining the package in the opened state, a PCBA or other electronic device/system may be inserted into the elastically deformed opening of the package. After the PCBA is in place, the force, F, may be removed from the package and the package will attempt to return from the elastically deformed state having expanded internal height dimension (HC+Y) to the original undeformed state having internal height dimension HC. In some embodiments, the package may be dimensioned and toleranced such that the height of the PCBA components is equal to or slightly greater than the internal height dimension HC in the original undeformed state. This dimensioning may provide a vertical clamping force on the components of the PCBA when the compressive, or opening, force is removed. Among other things, this clamping force may hold the PCBA inside the package and in direct conductive thermal communication with the housing. The heat generating elements of the PCBA may be in contact with the housing at one or more conduction cooling contact areas.

Heat generated from the PCBA inside the package may be passed through the housing to the cooling fins disposed on the outside of the housing walls. In some embodiments, a thermal interface material may be disposed between the heat generating elements on the PCBA and the conduction cooling contact areas prior to clamping the PCBA in place inside the package.

In some embodiments, the package may be sealed via one or more soldered, brazed, welded, and/or otherwise affixed endplates. The endplates may include one or more connectors to the PCBA and/or provide an electrical interconnection to the PCBA from the outside of the package. In some cases, these electrical connectors and/or electrical interconnections may be hermetically sealed, potted, and/or pseudo-hermetically sealed within the endplates.

As can be appreciated, the compact package described herein can provide efficient cooling of multi-surface electronics equipment in a hermetic and/or sealed environment. Further, due in part to the small size and passive cooling structure, the device is capable of being installed in any environment or area of a vehicle, machine, system, etc.

In some embodiments, the package may employ a multiple-flexure system in the extruded housing such that an elastic opening force may provide a linear translation (e.g., in the vertical direction) of one or more cooling contact surfaces of the housing. As the opening force is applied to the pressure contact area, the force displaces the angled flexures outwardly from the center of the package. This displacement results in a linear translation of each of the cooling contact surfaces creating a more even clamping pressure on the PCBA elements when the opening force is removed. It is an aspect of the present disclosure that the flexures may be sized and/or tuned to provide a desired clamping force against the one or more components of the PCBA.

Referring toFIGS. 1A-1C, various views of a printed circuit board assembly (PCBA)100are shown in accordance with embodiments of the present disclosure. In some embodiments, the features of the PCBA100may be described with reference to one or more axes (e.g., X-axis, Y-axis, Z-axis), or planes (e.g., XZ-plane, XY-plane, YZ-plane) of the coordinate system102shown. As shown, the PCBA100may include a substantially planar substrate104having a length, LS, running from a first end122to a second end126of the substrate104. This length, LS, and a width, WS, of the substrate104may define at least one substantially planar component mounting surface106A,106B disposed on the first side and/or second side of the substrate104. The first surface106A of the substrate104may be separated from the second surface106B of the substrate104by a thickness, or height, HS, corresponding to one or more layers of material making up the substrate104. In some embodiments, the length, LS, and width, WS, of the substrate104may correspond to the overall length and width of the PCBA100. The height, HS, of the substrate104, however, may differ from the height, HP, of the PCBA100. For example, the height, HP, of the PCBA may include an overall height of the components attached, soldered, fused, and/or protruding from one or more surfaces106A,106B of the PCBA100in addition to the height, HS, of the substrate100.

In some embodiments, the substrate104may correspond to a printed circuit board (PCB). In one embodiment, the substrate104may include one or more layers of dielectric material and at least one layer disposed thereon including electrically conductive traces120configured to electrically interconnect electronic components of the PCBA100. The traces120may run from one or more legs, contacts, or pins associated with passive electronic components (e.g., resistors, capacitors, diodes, transformers, etc.) and/or active electronic components (e.g., transistors, processors, application specific integrated circuit (ASIC), microprocessors, and/or other components configured to actively control electron flow, etc.) to one or more other components, connectors, and/or ground features associated with the PCBA100. In some embodiments, the traces120may pass from a first surface106A or side of the PCBA100to a second surface106B or side of the PCBA100.

The substrate104may be made from rigid material configured to mechanically support the electronic components. Examples of the rigid materials may include, but are in no way limited to, fiberglass, linen, ceramic, glass, resin, epoxy, phenolic cotton paper, woven fiberglass cloth, glass and polyester, paper and epoxy, insulated metal, polymer, polyimide, polytetrafluoroethylene, etc., and/or combinations thereof. The electrically conductive traces120of the substrate104may be machined, stamped, cut, etched, deposited, and/or otherwise formed from a conductive material. Examples of conductive materials may include, but are in no way limited to, copper, silver, gold, aluminum, graphene, etc., and/or other metals. For clarity of description, a limited number of traces120are shown inFIGS. 1A-1C.

As shown inFIGS. 1A-1C, the PCBA100may include a number of heat generating elements108A-D, including at least one surface110A-D from which heat may be transferred and/or emitted. The heat generating elements108A-D may correspond to passive or active electronic components. In one embodiment, the heat generating elements108A-D may be microprocessors, processors, and/or integrated circuits. The heat generating elements108A-B may be attached to a first surface106A of the substrate104via surface mount and/or through-hole mount soldering and/or via at least one adhesive layer disposed between the heat generating elements108A-B and the first surface106A. Heat generating elements108C-D may be attached to a second surface106B of the substrate104via surface mount and/or through-hole mount soldering and/or via at least one adhesive layer disposed between the heat generating elements108C-D and the second surface106B. In some embodiments, the first surface106A may be disposed opposite the second surface106B, or vice versa, separated by a material or substrate thickness, HS.

In addition to one or more heat generating elements108A-D, the PCBA100may include other electronic components112A,112B, connectors116A,116B, electrical contacts, and/or mechanical features. The connectors116A,116B may correspond to communications connectors, power connectors, and/or a combination of communications and power connectors. In some embodiments, the connectors116A,116B may be disposed at the same end126of the substrate104or PCBA100. Among other things, locating the connectors116A,116B at the same end126of the PCBA100allows a single end of the package to house the mating connections and/or passthrough electrical interconnections from an interior of the sealed package to an exterior of the sealed package.

In some embodiments, the PCBA100may include a plurality of heat generating elements108A-D disposed on one or more sides or surfaces106A,106B of the substrate104.FIG. 1Cshows first and second heat generating elements108A,108B disposed on the first surface106A of the substrate, while third and fourth heat generating elements108C,108D are shown disposed on the second surface106B of the substrate104. As provided above, the overall height, HP, of the PCBA100may be measured between points of the PCBA100that are disposed furthest from the substrate104(e.g., extending outwardly along the Y-axis). For example, the heat generating elements108A-D are the tallest electronic components attached to the first and second surfaces106A,106B, respectively, on either side of the substrate104. In this example, the overall height, HP, of the PCBA100may be measured from the heat emitting surface110B of the second heat generating element108B to the heat emitting surface110C of the third heat generating element108C. The heat emitting surfaces110A-D of the heat generating elements108A-D may be substantially planar and/or substantially parallel to the first and/or second surfaces106A,106B of the substrate104.

FIG. 2Ashows a perspective view of a sealable multi-surface electronics thermal conduction package200in accordance with embodiments of the present disclosure. The package200may comprise a body including a profile, or extrusion, surface204and shape having a first end208A, a second end208B, a first contact surface212A (not shown inFIG. 2A), a second contact surface212B, and a hollow space, or electronics receiving cavity,220disposed therebetween. The package200may include a number of heat sink elements216configured to transfer thermal energy from a surface of the body to an environment surrounding the body. The heat sink elements216may be configured as straight fins, protrusions, pins, flared fins, etc., and/or combinations thereof. In some embodiments, the heat sink elements216may extend along a length of the package200, for example, from the front222(e.g., at the profile surface204) to the rear226of the package200.

In some embodiments, the package200may include one or more controlled bend regions, areas, or flexures,224. As shown inFIG. 2A, the package200includes flexures224disposed at an approximate center of the package200, in both the upper and lower portions206A,206B of the profile surface204. The flexures224may be shaped such that a force applied to the first and/or second contact surfaces212A,212B of the package200displaces the upper and lower portions206A,206B of the package200in a direction (e.g., the Y-axis direction) away from the center of the package200.

The package200may be made from plastic, metal, carbon fiber, linen, composites, epoxy resin, etc., and/or combinations thereof. In one embodiment, the material of the package200may be thermally conductive. Thermally conductive material may provide a thermal path from an interior space220of the package200to an environment outside the package. This thermal path may serve as the path by which heat can be transferred from electronics contained inside the package200. Examples of thermally conductive materials may include, but are in no way limited to, steel, titanium, aluminum, copper, tin, nickel, iron, etc., alloys thereof, and/or combinations thereof. The package200may be machined, formed, molded, cast, extruded, etc., and/or combinations thereof. In one embodiment, the material of the package200may be extrudable and thermally conductive. One example of an extrudable and thermally conductive material is aluminum. In any event, the package200may be designed such that the profile surface204defines a shape corresponding to at least one shape of an extrusion die used to create the package200. In this example, the package200may be formed by heating and softening a billet of extrudable material (e.g., aluminum, etc.), forcing the billet of extrudable material through one or more extrusion dies (e.g., including the features, or inverse features, of the profile shape204, etc.), cooling the extruded material as it exits the one or more extrusion dies, and then cutting the extruded material to length. Once extruded and cut to length, the body can be deburred, cleaned, machined, and/or finished (e.g., coated, anodized, nickel plated, etc.). The extruded body provides a cost-effective and integral, one-piece, housing for the sealable multi-surface electronics thermal conduction package200.

FIGS. 2B and 2Cshows front elevation views of the sealable multi-surface electronics thermal conduction package200ofFIG. 2Ain various assembly states in accordance with embodiments of the present disclosure. In particular,FIG. 2Bshows the package200in a normal, uncompressed, or first state andFIG. 2Cshows the package200in a compressed, or second state, where the force of compression causes the opening, or receiving cavity,220to open in the Y-axis direction. In some embodiments, the package200may be centerline symmetrical, for example, along a centerline running through the center of the package200along the X-axis and/or along a centerline running through the center of the package200along the Y-axis.

As shown inFIG. 2B, the package200in the first or normal state provides a receiving cavity220, configured as a hollow space in the center of the package200, having a cavity height, HC. The cavity height, HC, may be defined as a distance between a first interior surface of the package200and a second opposing interior surface of the package200along the Y-axis. This cavity height, HC, may remain substantially the same along the X-axis direction from a position adjacent to the first end208A of the package200to a position adjacent to the second end208B of the package200. Additionally or alternatively, the cavity height, HC, may remain substantially the same along the length of the package (e.g., along the Z-axis direction). In some embodiments, the cavity height, HC, may be sized to substantially match an overall height, HP, of the PCBA100(see, e.g.,FIG. 1C). In one embodiment, the cavity height, HC, may be undersized, or sized less than the overall height, HP, of the PCBA100, by an amount to provide a clamping, or holding, force on any electronics (e.g., the PCBA100, etc.) disposed inside the receiving cavity220. In another embodiment, the cavity height, HC, may be oversized, or sized greater than the overall height, HP, of the PCBA100, by an amount to allow a thermal interface material to be inserted between any inserted electronics (e.g., the PCBA100, etc.) and the interior surfaces of the receiving cavity220.

InFIG. 2C, the package200has been compressed (e.g., in the X-axis direction) by an applied force230such that the first end208A and the second end208B of the package200are displaced closer together toward the center of the package200. In this second state, the width of the package200(e.g., the dimension from the first contact surface212A to the second contact surface212B) is less than the width of the package200in the first state. As the applied force230moves the first and second ends208A,208B closer together, the force230simultaneously moves the upper portion206A and the lower portion206B apart from one another (e.g., in a direction away from the center of the package200along the Y-axis). The displacement of the upper and lower portions206A,206B increases the cavity height, HC, by an opening distance, Y. As shown inFIG. 2C, the flexures224control the movement direction and displacement of the upper and lower portions206A,206B when the force230is applied and/or removed. In some embodiments, the increased cavity height, (HC+Y), may provide enough clearance inside the receiving cavity220to allow a PCBA100, or other electronics, to be inserted therein. In some embodiments, the structure of the package200may prevent a PCBA100from being inserted into the receiving cavity220in the first state (e.g., because the cavity height, HC, may be substantially similar to, or less than, the overall height, HP, of the PCBA100, etc.) and only allow insertion of the PCBA100when the package200is flexed, in the second state. Although shown as displacing angularly from the first and second ends208A,208B, (e.g., relative to the XZ-plane, etc.) it should be appreciated that the flexures224and/or structure of the profile shape204of the package200may be configured (e.g., adding more flexures, shaping each flexure, including a controlled pivot area, etc., and/or combinations thereof) to provide a linear, or substantially orthogonal, translation of the interior surfaces relative to the XZ-plane.

It is an aspect of the present disclosure that the package200may be elastically flexed from the first state (e.g., shown inFIG. 2B) to the second state (e.g., shown inFIG. 2C), and vice versa. For instance, the material of the package200and design of the flexures224may allow the package200to be repeatedly flexed within the elastic range of the package material. Additionally or alternatively, the package200may elastically return from the second state to the first state when the applied force230is removed from the package200. This return from the second state to the first state may occur without the application of any external force (e.g., force applied to the package200, etc.). For example, the elastic energy (e.g., potential mechanical energy) stored in the package200in the second state may be converted into kinetic energy substantially moving the package200back to the first state when the applied force230is removed from the package200.

FIGS. 3A and 3Bshow front elevation views of the package200during assembly stages inserting electronics, such as a PCBA100, into the receiving cavity220. InFIG. 3A, the package200is shown in the second, or flexed, state. While in the flexed state, the applied force230holds, or maintains, the package200in an “open” configuration where the receiving cavity has an increased cavity height, (HC+Y). In the second state, the increased cavity height, (HC+Y) provides clearance304around the heat generating elements108A-D and/or other electronic components. The clearance304allows the PCBA100to be inserted into the receiving cavity220of the package200. In some embodiments, and while in the second state, the clearance304may allow the PCBA100to be inserted into the receiving cavity220of the package200without any interference or restriction between the PCBA100and the package200.

InFIG. 3B, the package200is shown in the first, or substantially unflexed, state. As described above, the package200may be unflexed (e.g., having no applied force230flexing the package200, etc.) but may provide a clamping force against the heat generating elements108A-D holding the PCBA100in place inside the receiving cavity220of the package200. As shown inFIG. 3B, at least one interior surface of the upper portion206A of the package200is contacting the upper heat generating elements108A-B at thermal contact areas308, while at least one interior surface of the lower portion206B of the package200is contacting the lower heat generating elements108CA-D at opposing thermal contact areas308. The interior surfaces of the receiving cavity220may be in contact, or coplanar, with the heat emitting surfaces110A-D of the heat generating elements108A-D. In some embodiments, a thermal interface material (TIM) may be disposed between the at least one interior surface of the receiving cavity220and the heat generating elements108A-D. The TIM may be a thermally conductive grease, tape, adhesive, or other thin material configured to provide an effective thermal path (e.g., a thermal coupling, etc.) between the heat generating elements108CA-D of the PCBA100and the material of the package200.

Referring now toFIGS. 4A-4F, perspective views of different steps in an assembly process for the sealable multi-surface electronics thermal conduction package with integrated electronics400are shown in accordance with embodiments of the present disclosure. In some embodiments, the method of manufacturing described in conjunction withFIG. 6may correspond to one or more of the steps illustrated in conjunction withFIGS. 4A-4F.

As shown inFIG. 4A, a package200is provided in a first, unflexed, state prepared for electronics integration. The package200may correspond to any of the packages200,500described herein. The PCBA100may be aligned with the receiving cavity220of the package200inFIG. 4A. In some embodiments, the front122of the PCBA100or the rear126of the PCBA100may be inserted into the receiving cavity220first. The receiving cavity220may be open on one or more of a front222and/or rear222of the package200. In some cases, the PCBA100may be inserted in either open end (e.g., the front222and/or rear222) of the receiving cavity220.

InFIG. 4B, the package200may be opened into the second, flexed, state by applying a compressive force230to the first and/or second contact surfaces212A,212B of the package200. As provided above, this compressive force230may increase an internal dimension (e.g., the cavity height, HC, by an opening distance, Y. The increased internal dimension of the receiving cavity220may provide clearance304for the PCBA100to be inserted therein. Once aligned with the receiving cavity220, the PCBA100may be moved, in an insertion direction430, into the package200, while the compressive force230is continually applied to the package200.

The PCBA100may be oriented, located, or otherwise positioned inside the package200while the compressive force230is maintained, as shown inFIG. 4C. InFIG. 4C, the PCBA100is shown completely inside the receiving cavity220. Once the PCBA100is positioned inside the receiving cavity220relative to the front222and/or rear226of the package200, the compressive force230may be released. Releasing the compressive force230may allow the package to substantially return from the second state to the first state, as illustrated inFIG. 4D.

Next, the package200may be sealed with one or more endplates404,408, as shown inFIGS. 4E and 4F. The endplates404,408may substantially match the geometry or shape of an end222,226of the package200. In some embodiments, the endplates404,408may substantially follow a shape of the profile surface204of the package200. In any event, the endplates404,408may be adhered, affixed, brazed, welded, or otherwise attached to the ends222,226of the package200, respectively. It is an aspect of the present disclosure that the endplates404,408when attached to the package200may hermetically seal the package200and, more specifically, seal the interior space of the receiving cavity220including the PCBA100from an environment outside of the receiving cavity220.

In some embodiments, one or more of the endplates404,408may include a number of connectors, electrical interconnections, or other interconnection features412or passthroughs formed in a portion of the endplate404,408. The connectors116A,116B of the PCBA100may be interconnected with one or more of these interconnection features412providing a conductive path for one or more of communication and power between the inside of the sealed receiving cavity220and the outside of the package200. As shown inFIG. 4E, the rear endplate408includes a series of interconnection features412configured as a series of small sealed connectors416, pins, and/or sealable passthroughs418. In some embodiments, the sealed connectors416may be configured as one or more conductive pins disposed in respective holes of the endplate408, where the hole is filled with a potting material. In one embodiment, the pins may be surrounded by glass forming a glass to metal seal between the pins and the holes in the endplate408. In some cases, a pseudo-hermetic seal may be achieved via a passthrough connector disposed in an opening, aperture, or hole in the endplate408, the passthrough connector sealed in the opening, aperture, or hole by one or more gaskets and/or O-rings. The completed sealable multi-surface electronics thermal conduction package with integrated electronics400(e.g., with endplates404,408sealed to the package200, etc.) is shown in the perspective view ofFIG. 4F.

In some embodiments, the operations of assembly described herein may be reversed to rework or disassemble the package200and/or remove or replace the PCBA100from the package200.

FIG. 5Ashows a perspective view of a sealable multi-surface electronics thermal conduction package500in accordance with embodiments of the present disclosure. The package500show inFIGS. 5A-5Dmay include similar, if not identical, features to those described in conjunction with the package200shown inFIGS. 2A-2C. As can be appreciated, the description of the package200, or the assembly of the PCBA100in the package200, may apply to the package500shown inFIGS. 5A-5D, and vice versa.

The package500may comprise a body including a profile, or extrusion, surface504and shape having a first end508A, a second end508B, a first contact surface512A (not shown inFIG. 5A), a second contact surface512B, and a hollow space, or electronics receiving cavity,520disposed therebetween. The package500may include a number of heat sink elements516configured to transfer thermal energy from a surface of the body (e.g., inside the receiving cavity520, etc.) to an environment surrounding the body. The heat sink elements516may be configured as straight fins, protrusions, pins, flared fins, etc., and/or combinations thereof. In some embodiments, the heat sink elements516may extend along a length of the package500, for example, from the front522(e.g., at the profile surface504) to the rear526of the package500.

In some embodiments, the package500may include one or more controlled bend regions, areas, or flexures,524. As shown inFIGS. 5A-5D, the package500may include symmetrical sets of flexures524disposed about a center544of the package500. In some embodiments, and as shown inFIG. 5B, the package500may be centerline symmetrical about center planes passing through the center544of the package500. For instance, the package500may be symmetrical about the YZ-plane running through the center544of the package500and/or symmetrical about the XZ-plane running through the center544of the package500. The flexures524may be shaped such that a force530applied to the first and/or second contact surfaces512A,512B of the package500displaces the upper and lower portions506A,506B of the package500in a direction (e.g., the Y-axis direction) away from the center of the package500. The orientation of the flexures524in the package500may provide a linear and/or substantially orthogonal translation of the upper and lower portions506A,506B from the center544of the package500. Among other things, this linear movement may allow the internal heat contacting surfaces of the package500(e.g., the surfaces disposed inside the receiving cavity520, etc.) to move such that they may remain substantially parallel (e.g., to one another) and/or substantially orthogonal to the first and/or second contact surfaces512A,512B of the package500.

In some embodiments, the package500may include one or more PCB substrate channels532. The PCB substrate channels532may be sized to receive and locate the PCB substrate104inside the receiving cavity520of the package500. In some cases, the PCB substrate channels532may capture one or more edges of the PCB substrate104, preventing the PCBA100from moving in the Y-axis direction inside the receiving cavity520. The PCB substrate channels532may be sized to allow some movement of the PCBA100along the X-axis inside the receiving cavity520and/or allow the sides508A,508B of the package500to move relative to the PCBA100when compressed and/or released.

The package500may include one or more end-of-travel (EOT) stops536,540to prevent over-flexing of the flexures524(e.g., where, without the stops, squeezing the package500could force the flexures524past their elastic range, etc.) during assembly and/or disassembly. In some embodiments, these EOT stops536,540may be built into the profile504, body, extruded shape, and/or other portion of the package500. In one embodiment, a compression EOT stop536may be built into a portion of the heat transfer contacting surfaces adjacent to the first and second sides508A,508B of the package500. This compression EOT stop536may serve to resist movement of the sides508A,508B of the package500from compressing beyond a predefined amount or distance by, for example, contacting an internal portion of the sides508A,508B of the package500at a maximum compression (e.g., a compression amount determined to provide ample clearance304for inserting the PCBA100, etc.). In some embodiments, a vertical displacement EOT stop540may prevent the upper and lower portions506A,506B from extending outwardly from the center544of the package500beyond a predefined amount or distance by, for example, contacting an internal portion of the upper and lower portions506A,506B of the package500at a maximum displacement (e.g., a displacement amount determined to provide ample clearance304inside the receiving cavity520for inserting the PCBA100without restriction, etc.)

Similar to the package200described in conjunction withFIGS. 2A-C, the package500may be made from plastic, metal, carbon fiber, linen, composites, epoxy resin, etc., and/or combinations thereof. In one embodiment, the material of the package500may be thermally conductive. Thermally conductive material may provide a thermal path from an interior space520of the package500to an environment outside the package. This thermal path may serve as the path by which heat can be transferred from electronics contained inside the package500. Examples of thermally conductive materials may include, but are in no way limited to, steel, titanium, aluminum, copper, tin, nickel, iron, etc., alloys thereof, and/or combinations thereof. The package500may be machined, wire electrical discharge machined (EDM), formed, molded, cast, extruded, etc., and/or combinations thereof. In one embodiment, the material of the package500may be extrudable and thermally conductive. One example of an extrudable and thermally conductive material is aluminum. In any event, the package500may be designed such that the profile surface504defines a shape corresponding to at least one shape of an extrusion die used to create the package500. In this example, the package500may be formed by heating and softening a billet of extrudable material (e.g., aluminum, etc.), forcing the billet of extrudable material through one or more extrusion dies (e.g., including the features, or inverse features, of the profile shape504, etc.), cooling the extruded material as it exits the one or more extrusion dies, and then cutting the extruded material to length. Once extruded and cut to length, the body can be deburred, cleaned, machined, and/or finished (e.g., coated, anodized, nickel plated, etc.). The extruded body provides a cost-effective and integral, one-piece, housing for the sealable multi-surface electronics thermal conduction package500.

FIG. 5Bshows a front elevation view of the sealable multi-surface electronics thermal conduction package500ofFIG. 5A. As provided above, the package500may be centerline symmetrical, for example, along a centerline running through the center544of the package500along the X-axis and/or along a centerline running through the center544of the package500along the Y-axis. The package500shown inFIG. 5B, may correspond to a first, unflexed, or normal state including a receiving cavity520, configured as a hollow space in the center of the package500. The package500may have a cavity height, HC, as previously described in conjunction withFIGS. 2A-2C. The cavity height, HC, may be defined as a distance between a first interior surface of the package500and a second opposing interior surface of the package500along the Y-axis. This cavity height, HC, may remain substantially the same along the X-axis direction from a position adjacent to the first end508A of the package500to a position adjacent to the second end508B of the package500. Additionally or alternatively, the cavity height, HC, may remain substantially the same along the length of the package (e.g., along the Z-axis direction). In some embodiments, the cavity height, HC, may be sized to substantially match the overall height, HP, of the PCBA100(see, e.g.,FIG. 1C). In one embodiment, the cavity height, HC, in the unflexed state may be undersized, or sized less than the overall height, HP, of the PCBA100, by an amount to provide a clamping, or holding, force on any electronics (e.g., the PCBA100, etc.) disposed inside the receiving cavity520. In another embodiment, the cavity height, HC, may be oversized in the unflexed state, or sized greater than the overall height, HP, of the PCBA100, by an amount to allow a thermal interface material to be inserted between any inserted electronics (e.g., the PCBA100, etc.) and the interior surfaces of the receiving cavity520.

FIGS. 5C and 5Bshow front elevation views of the package500during assembly stages inserting electronics, such as the PCBA100, into the receiving cavity520. InFIG. 5C, the package500is shown in the second, or flexed, state. In particular, as the sides508A,508B of the package500are compressed, or squeezed, together (e.g., toward the center544) causing the upper and lower portions506A,506B of the package500to move outwardly, from the center544, and away from one another, in a linear direction550along the Y-axis. While in the flexed state, the applied force530holds, or maintains, the package500in an “open” configuration where the receiving cavity has an increased cavity height, (HC+Y). In the second state, the increased cavity height, (HC+Y) provides clearance304around the heat generating elements108A-D and/or other electronic components of the PCBA100. The clearance304allows the PCBA100to be inserted into the receiving cavity520of the package500. In some embodiments, and while in the second state, the clearance304may allow the PCBA100to be inserted into the receiving cavity520of the package500without any interference or restriction between the PCBA100and the package500. As shown inFIG. 5C, the clearance304provided by the displacement of the upper and lower portions506A,506B of the package500is the same at any point along the heat generating elements108A-D. For example, the clearance304provides a space between the heat emitting surfaces110A-D of the heat generating elements108A-D and the substantially parallel internal heat contacting surfaces of the receiving cavity520.

InFIG. 5D, the package500is shown in the first, or substantially unflexed, state. As described above, the package500may be unflexed (e.g., having no applied force530flexing the package500, etc.) but may provide a clamping force against the heat generating elements108A-D holding the PCBA100in place inside the receiving cavity520of the package500. As shown inFIG. 5D, at least one interior surface of the upper portion506A of the package500is contacting the upper heat generating elements108A-B at thermal contact areas308, while at least one interior surface of the lower portion506B of the package500is contacting the lower heat generating elements108CA-D at opposing thermal contact areas308. The interior surfaces of the receiving cavity520may be in contact, or coplanar, with the heat emitting surfaces110A-D of the heat generating elements108A-D. In some embodiments, a thermal interface material (TIM) may be disposed between the at least one interior surface of the receiving cavity520and the heat generating elements108A-D. The TIM may be a thermally conductive grease, tape, adhesive, or other thin material configured to provide an effective thermal path (e.g., a thermal coupling, etc.) between the heat generating elements108CA-D of the PCBA100and the material of the package500.

FIG. 6is a flow diagram of a method600for assembling electronics in a sealable multi-surface electronics thermal conduction package200,500in accordance with embodiments of the present disclosure. While a general order for the steps of the method600is shown inFIG. 6, the method600can include more or fewer steps or can arrange the order of the steps differently than those shown inFIG. 6. Generally, the method600starts with a start operation604and ends with an end operation632. The method600can be executed as a set of computer-executable instructions executed by an assembly machine (e.g., robotic assembly system, automation assembly system, etc.) and encoded or stored on a computer readable medium. Hereinafter, the method600shall be explained with reference to the components, devices, assemblies, environments, etc. described in conjunction withFIGS. 1-5D.

The method600may begin at step604and continue by providing a thermal control package, for example, the package200,500(step608). In some embodiments, the provided package200,500may be cleaned, deburred, coated, plated, and/or finished. Next, the method600continues by positioning an electronics assembly, for example, a PCBA100relative to the package200,500(step612). In some embodiments, positioning the PCBA100relative to the package200,500may include aligning the PCBA100with the receiving cavity220,520of the package200,500. Steps608and612, providing the package200,500and positioning the PCBA100relative to the package200,500may be provided as shown and described in conjunction withFIG. 4Aabove.

Once the PCBA100is aligned with the receiving cavity220,520, the package200,500may be compressed by applying at least one compressive force230,530to the sides208A,208B,508A,508B of the package200,500(step616). As described above, the compressive force230,530may open a dimension of the receiving cavity220,520to receive the PCBA100. In one embodiment, the package200,500may be compressed via a vise, gripper, or other device. The compression device may be screw-actuated, pneumatically-actuated, hydraulically-actuated, etc., and/or combinations thereof. While the package200,500is compressed, expanding a dimension (e.g., height, HC) of the receiving cavity220,520, the PCBA100may be inserted into the receiving cavity220,520without restriction (step620). In some embodiments, while the package200,500is maintained in the second (compressed/flexed) state, the position of the PCBA100may be adjusted inside the package200(e.g., along the Z-axis direction, etc.). This adjustment may ensure that the ends122,126of the PCBA100are disposed between, and not extending past, the ends222,226,522,526of the package200,500. These steps616,620may correspond to the steps illustrated and described in conjunction withFIGS. 4B and 4Cabove.

When the PCBA100is properly positioned inside the package200,500, (e.g., inside the receiving cavity220,520, etc.) the method600may continue by releasing the compressive force230,530from the sides208A,208B,508A,508B of the package200,500(step624). Releasing the force230,530allows the elastic energy of the package200,500stored in, for example, the flexures224,524to be converted into kinetic energy moving the package from the second, flexed, state to the first, unflexed, state. This elastic movement allows the package200,500to automatically return to a substantially unflexed state without requiring any application of a force external to the material of the package200,500.

Next, the method600may proceed by attaching the endplates404,408to the package200,500(step628). The endplates404,408may be adhered, affixed, brazed, welded, or otherwise attached to the ends222,226,522,526of the package200,500, respectively. It is an aspect of the present disclosure that the endplates404,408when attached to the package200may hermetically seal the package200,500and, more specifically, seal the interior space of the receiving cavity220,520including the PCBA100from an environment outside of the receiving cavity220,520. In some embodiments, (e.g., prior to attaching the endplates404,408to the package200,500) the connectors116A,116B of the PCBA100may be interconnected to the one or more interconnection features412disposed on at least one of the endplates404,408. This interconnection may provide a conductive path for one or more of communication and/or power between the inside of the sealed receiving cavity220,520and the outside of the package200,500.

In some embodiments, one of the endplates404,408may be attached to the package200,500before the other of the endplates408,404is attached to the package200,500. After one of the endplates404,408is attached to the package200,500, the receiving cavity220,520of the package200,500, specifically the areas in between the interior surfaces of the receiving cavity220,520and the surfaces of the PCBA100may be filled with a material. The material may be a gas, a dielectric material, a thermally conductive material, an epoxy potting compound, etc., and/or combinations thereof. The material may provide protection of the components (e.g., electronic components, PCBA100, etc.) inside the receiving cavity220,520. In one embodiment, the material may provide enhanced thermally conductive pathways between the various components of the PCBA100and the interior surfaces of the receiving cavity220,520. The material may be inserted as a fluid that, when cured, hardens in the open spaces between the PCBA100and the interior surfaces of the receiving cavity220,520. The material can secure the components of the PCBA100in place inside the receiving cavity220,520, and relative to one another, providing enhanced shock resistance and protection from failures due to separation of components from the PCBA100. In some embodiments, the material inserted may serve to prevent corrosion of the electronic components inside the receiving cavity220,520(e.g., providing an inert reactive environment, etc.). Once filled and/or cured, the other endplate408,404may be attached to the opposite end of the package200,500sealing the PCBA100inside the receiving cavity220,520. In any event, attaching the endplates404,408and sealing the package200,500forming the complete sealable multi-surface electronics thermal conduction package with integrated electronics400may correspond to the steps illustrated and described in conjunction withFIGS. 4E and 4Fabove. The method600ends at step632.

It is an aspect of the present disclosure that a complete sealable multi-surface electronics thermal conduction package with integrated electronics400may be reworked, disassembled, or otherwise modified. In this case, the steps described in conjunction withFIG. 6may be reversed to open the integrated package400. For example, disassembling at least a portion of the integrated package400may include first detaching one or more of the endplates404,408from the package200,500(e.g. the reverse of step628). This detachment may include cutting, machining, or otherwise separating at least one of the endplates404,408from the body of the package200,500. Once at least one of the endplates404,408has been removed, the package200,500may be compressed to release the PCBA100from the receiving cavity220,520(e.g., the reverse of step624). The reverse method may continue by removing the PCBA100, releasing the compressive force from the package200,500, and separating the parts making up the PCBA100and package200,500.

In the event that the PCBA100is to be replaced, the reverse method may be performed up to the point that the PCBA100is separated from the package200,500and then the method600may be repeated (e.g., at step612) to insert a new PCBA100in the receiving cavity220,520. The method600may proceed until the new PCBA100is sealed inside the package200,500forming the integrated package400(step628).

A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others. In some embodiments, the present disclosure provides an electrical interconnection device that can be used between any electrical source and destination. While the present disclosure describes connections between battery modules and corresponding management systems, embodiments of the present disclosure should not be so limited.

Embodiments include an electronics package, comprising: a body having a peripheral shape including a first side and an opposite second side, and an upper portion and a lower portion disposed between the first and second sides, the peripheral shape extending along a length, the body including a first end surface disposed at a first end of the length and a second end surface disposed at a second end of the length; a receiving cavity disposed inside the peripheral shape between the first and second sides and the upper and lower portions, the receiving cavity passing through the body from the first end surface to the second end surface; and a controlled bend feature disposed in the upper portion of the peripheral shape of the body, wherein the controlled bend feature includes an elastically flexible region of material shaped to direct forces applied to the first and/or second sides along the upper portion and in a direction outwardly from a center of the receiving cavity.

Aspects of the above electronics package include wherein the controlled bend feature includes a cross-sectional area less than a cross-sectional area of the upper portion. Aspects of the above electronics package include wherein the body has an unflexed state and a flexed state, wherein in the unflexed state the receiving cavity includes an interior height running the length of the body, wherein in the flexed state the receiving cavity has an increased interior height running the length of the body, wherein in the unflexed state a first distance separates the first side from the second side and the interior height separates the upper portion from the lower portion, and wherein in the flexed state the first side and second side are separated by a second distance less than the first distance and the upper portion and lower portion are separated from one another by the increased interior height. Aspects of the above electronics package further comprising: a controlled bend feature disposed in the lower portion of the peripheral shape of the body; and a plurality of heat sink elements formed in the upper portion and lower portion and extending from the peripheral shape of the body in a direction outwardly from a center of the body, wherein a first thermal conductive path is formed between a first interior surface of the receiving cavity and the plurality of heat sink elements formed in the upper portion, and wherein a second thermal conductive path is formed between an opposite second interior surface of the receiving cavity and the plurality of heat sink elements formed in the lower portion. Aspects of the above electronics package include wherein the body, the receiving cavity, and the controlled bend features are integrally formed from a single extruded material. Aspects of the above electronics package include wherein the controlled bend feature disposed in the upper portion of the peripheral shape includes a first set of flexures running the length of the body, and wherein the controlled bend feature disposed in the lower portion of the peripheral shape includes a second set of flexures running the length of the body. Aspects of the above electronics package include wherein each of the first set of flexures is disposed at a non-zero angle relative to the first interior surface, and wherein each of the second set of flexures is disposed at a non-zero angle relative to the second interior surface. Aspects of the above electronics package include wherein the upper portion and the lower portion include end-of-travel stops arranged to limit a displacement amount of the first and second sides of the body between the unflexed and flexed states. Aspects of the above electronics package include wherein the receiving cavity includes a set of printed circuit board (PCB) channels running the length of the body and sized to receive and capture at least a portion of a PCB substrate.

Embodiments include an integrated electronics package, comprising: a body having a peripheral shape including a first side and an opposite second side, and an upper portion and a lower portion disposed between the first and second sides, the peripheral shape extending along a length, the body including a first end surface disposed at a first end of the length and a second end surface disposed at a second end of the length; a receiving cavity disposed inside the peripheral shape between the first and second sides and the upper and lower portions, the receiving cavity passing through the body from the first end surface to the second end surface; a controlled bend feature disposed in the upper and lower portions of the peripheral shape of the body, wherein the controlled bend feature includes an elastically flexible region of material shaped to direct forces applied to the first and/or second sides along the upper and lower portions and in a direction outwardly from a center of the receiving cavity; and a printed circuit board assembly (PCBA) disposed in the receiving cavity and between the first and second end surfaces of the body.

Aspects of the above integrated electronics package further comprising: a first endplate substantially matching the peripheral shape of the body; and a second endplate substantially matching the peripheral shape of the body, wherein the first endplate is mechanically attached to the first end surface, wherein the second endplate is mechanically attached to the second end surface, and wherein an environment surrounding the PCBA inside the receiving cavity is sealed from an environment outside the receiving cavity. Aspects of the above integrated electronics package include wherein a set of hermetically-sealed electrical interconnection features are disposed in the second endplate, the hermetically-sealed electrical interconnection features providing an electrical conduit between the environment inside the receiving cavity and the environment outside the receiving cavity, and wherein the PCBA is electrically connected to the hermetically-sealed electrical interconnection features inside the receiving cavity. Aspects of the above integrated electronics package further comprising: a plurality of heat sink elements formed in the upper and lower portions and extending from the peripheral shape of the body in a direction outwardly from a center of the body, wherein a first thermal conductive path is formed between a first interior surface of the receiving cavity and the plurality of heat sink elements formed in the upper portion, and wherein a second thermal conductive path is formed between an opposite second interior surface of the receiving cavity and the plurality of heat sink elements formed in the lower portion. Aspects of the above integrated electronics package include wherein a first thermal interface material is disposed between the first interior surface and a first heat generating element of the PCBA. Aspects of the above integrated electronics package include wherein a second thermal interface material is disposed between the second interior surface and a second heat generating element of the PCBA, wherein the first heat generating element of the PCBA is disposed on a first side of a substrate of the PCBA, and wherein the second heat generating element of the PCBA is disposed on an opposite second side of the substrate of the PCBA. Aspects of the above integrated electronics package include wherein the body, the receiving cavity, and the controlled bend features are integrally formed from a single extruded material. Aspects of the above integrated electronics package further comprising: a set of printed circuit board (PCB) channels running the length of the body, wherein the PCBA is at least partially captured in the PCB channels. Aspects of the above integrated electronics package include wherein the environment surrounding the PCBA inside the receiving cavity is filled with a potting material.

Embodiments include a method of assembling an integrated electronics package, comprising: providing an electronics package, comprising: a body having a peripheral shape including a first side and an opposite second side, and an upper portion and a lower portion disposed between the first and second sides, the peripheral shape extending along a length, the body including a first end surface disposed at a first end of the length and a second end surface disposed at a second end of the length; a receiving cavity disposed inside the peripheral shape between the first and second sides and the upper and lower portions, the receiving cavity passing through the body from the first end surface to the second end surface; and a controlled bend feature disposed in the upper and lower portions of the peripheral shape of the body, wherein the controlled bend feature includes an elastically flexible region of material shaped to direct forces applied to the first and/or second sides along the upper and lower portions and in a direction outwardly from a center of the receiving cavity; aligning a printed circuit board assembly (PCBA) with the receiving cavity of the body; applying a compressive force to the first and/or second side of the body, wherein the compressive force flexes the controlled bend features and moves the upper portion and lower portion in opposite directions outwardly from the center of the receiving cavity providing a PCBA clearance height inside the receiving cavity; inserting the PCBA into the receiving cavity having the PCBA clearance height, while the compressive force is maintained, wherein the PCBA is positioned between the first and second ends of the body; releasing the compressive force applied, wherein upon releasing the compressive force applied the controlled bend features return to an unflexed state moving the upper portion and lower portion in a direction toward the center of the receiving cavity providing a reduced PCBA clearance height clamping the PCBA inside the receiving cavity; attaching a first endplate to the first end of the body; and attaching a second endplate to the second end of the body, wherein attachment of the first and second endplates isolate an environment surrounding the PCBA inside the receiving cavity from an environment outside the receiving cavity.

Aspects of the above method include wherein prior to attaching the second endplate, the method further comprises: inserting a potting material into the environment surrounding the PCBA inside the receiving cavity providing a mechanical connection between electronic components on the PCBA and interior surfaces of the receiving cavity.

Any one or more of the aspects/embodiments as substantially disclosed herein.

Any one or more of the aspects/embodiments as substantially disclosed herein optionally in combination with any one or more other aspects/embodiments as substantially disclosed herein.

One or more means adapted to perform any one or more of the above aspects/embodiments as substantially disclosed herein.