Systems and methods for passive cooling of electrical modules within electrical units

An electrical communications apparatus includes a support structure having a support heat transfer member. An electrical unit is received within the support structure. The electrical unit includes a module side defining a bore therethrough. The module side is arranged to receive an electrical module within the bore. The electrical unit further includes a conduction side adjacent the module side and a unit heat transfer member coupled to the conduction side. The unit heat transfer member and the support heat transfer member are correspondingly tapered to facilitate slidably coupling the unit heat transfer member and the support heat transfer member.

BACKGROUND

The present application relates generally to cooling electrical communications apparatuses and, more particularly, to structures for the passive cooling of electrical components disposed within electrical communications apparatuses.

Electrical components disposed within electrical and/or electro-mechanical systems, such as industrial communications systems, generate large amounts of heat. Such systems may be organized into a wide variety of electrical enclosures (e.g., electrical cabinets, electrical racks, etc.) that have a limited amount of space for the electrical components disposed therein. Indeed, the components disposed within these electrical enclosures may be densely packed within the limited amount of space, thereby leading to various thermal effects, such as the thermal degradation of the electrical components.

Accordingly, various heat dissipation techniques may be utilized within the electrical enclosures to help reduce the thermal effects on the electrical components. In some situations, active techniques related to air-cooling and/or water-cooling may be utilized to dissipate heat within these electrical systems. However, such techniques involve additional components, such as fans, filters, etc., that may increase the manufacturing cost, increase maintenance costs, occupy portions of the limited amount of space, and/or reduce the operating efficiency of the electrical systems. In addition, active cooling techniques, such as air-cooling and water-cooling techniques, generally often make use of moving components, such as bearing assemblies and rotors. As a result, such active cooling techniques may have higher rates of failure as compared to some passive cooling techniques. In particular, cooling techniques relying on air circulation within electrical enclosures are especially poorly suited for mission critical environments, such as power grid substations, where failure of active cooling systems can result in performance degradation or outages of electrical components. Further some electrical components, and in particular, small form factor pluggable devices, are manufactured in accordance with design parameters established by standard setting organizations. Moreover, such electrical components are designed to be removably pluggable and thus cannot be fixedly attached to traditional convection cooling apparatuses, such as, for example, a heat sink.

BRIEF DESCRIPTION

In one aspect, an electrical communications apparatus is provided. The electrical communications apparatus includes a support structure having a support heat transfer member. An electrical unit is received within the support structure. The electrical unit includes a module side defining a bore therethrough and arranged to receive an electrical module within the bore. The electrical unit further includes a conduction side adjacent the module side and a unit heat transfer member coupled to the conduction side. The unit heat transfer member and the support heat transfer member are correspondingly tapered to facilitate slidably coupling the unit heat transfer member and the support heat transfer member.

In another aspect, an electrical unit for use in an electrical communications apparatus is provided. The electrical unit includes a module side defining a bore therethrough and arranged to receive an electrical module within the bore. The electrical unit further includes a conduction side adjacent the module side and a unit heat transfer member coupled to the conduction side. The unit heat transfer member is tapered to facilitate slidably coupling the unit heat transfer member to a correspondingly tapered support heat transfer member of the electrical communications apparatus.

In yet another aspect, a method of using an electrical communications apparatus is provided. The method includes inserting an electrical unit into a support structure, the support structure including a support heat transfer member. The method further includes electrically coupling the electrical unit to a carrier. The electrical unit includes a module side defining a bore therethrough and arranged to receive an electrical module within the bore. The electrical unit further includes a conduction side adjacent the module side and a unit heat transfer member coupled to the conduction side. The unit heat transfer member and the support heat transfer member are correspondingly tapered to facilitate slidably coupling the unit heat transfer member and the support heat transfer member.

DETAILED DESCRIPTION

Specifically, as used herein, the terms “substantially transverse” or “substantially parallel” should be interpreted to include angles within 15 degrees of 90 degrees and 0 degrees respectively. Further, as used herein the term “substantially in contact” refers to having over a majority of the surface area of a first object being in contact with over a majority of the surface area of a second object.

An electrical communications apparatus includes a support structure having a support heat transfer member. An electrical unit is received within the support structure. The electrical unit includes a module side defining a bore therethrough and arranged to receive an electrical module within the bore. The electrical unit further includes a conduction side adjacent the module side and a unit heat transfer member coupled to the conduction side. The unit heat transfer member and the support heat transfer member are correspondingly tapered to facilitate slidably coupling the unit heat transfer member and the support heat transfer member.

FIG. 1is a perspective view of an exemplary electrical communications apparatus100with portions made transparent to allow for internal viewing of components. A coordinate system10includes an X-axis, a Y-axis, and a Z-axis.

In the exemplary embodiment, electrical communications apparatus100includes a support structure102and an electrical housing104. Support structure102includes a module end106and an external connection end108. In the exemplary embodiment, module end106includes an upper face110and an open end112defined beneath upper face110. Specifically, open end112is sized to receive electrical housing104therein. In the exemplary embodiment, support structure102further includes a first sidewall114, a second sidewall116opposite first sidewall114. First sidewall114and second sidewall116each extend from module end106to external connection end108. Further, in the exemplary embodiment, support structure102includes a top surface118and a bottom surface120transversely oriented to first sidewall114and second sidewall116and each extending in parallel from module end106to external connection end108. In the exemplary embodiment, support structure102is formed of a thermally conductive material. Specifically, support structure102is formed of an aluminum alloy. In alternative embodiments, support structure102is formed of any material that enables electrical communications apparatus100to function as described herein. In the exemplary embodiment, support structure102is an aluminum chassis. In alternative embodiments, support structure102includes any support structure that enables electrical communications apparatus100to function as described herein.

In the exemplary embodiment, electrical housing104is sized to be received within support structure102. Further, electrical housing104is removably coupled to support structure102. Specifically, in the exemplary embodiment, electrical housing104is inserted into support structure102through open end112of support structure102between first sidewall114and second sidewall116along a first direction parallel to the Z-axis. Similarly, electrical housing104is removable from support structure102in a second direction opposite the first direction and parallel to the Z-axis.

In the exemplary embodiment, electrical housing104includes a first sidewall122and a second sidewall124opposite first sidewall122. First sidewall122and second sidewall124of electrical housing104are arranged to extend adjacent first sidewall114and second sidewall116of support structure102when electrical housing104is received within support structure102.

In the exemplary embodiment, heat sinks126are coupled to first sidewall122and second sidewall124respectively. Heat sinks126are arranged to dissipate heat into a surrounding medium. Specifically, in the exemplary embodiment, heat sinks126are arranged to dissipate heat conducted from first sidewall114and second sidewall116into the support structure102. In the exemplary embodiment, heat sinks126are formed of a thermally conductive material. Specifically, in the exemplary embodiment, heat sinks126are formed of an aluminum alloy. In alternative embodiments, heat sinks126are formed of a copper alloy. In further alternative embodiments, heat sinks126are formed of any material that enables electrical communications apparatus100to function as described herein.

In the exemplary embodiment, electrical housing104includes an electrical unit128. Electrical unit128includes a module side130positioned at module end106of support structure102. Module side130defines a plurality of electrical connection bores (not shown) therethrough. In the exemplary embodiment, module side130defines six electrical connection bores arranged in two rows and three columns. In alternative embodiments, module side130defines only a single electrical connection bore thereon. In further alternative embodiments, module side130defines any number of electrical connection bores in any configuration that enables electrical unit128to function as described herein.

In the exemplary embodiment, an electrical module132is received within each of the electrical connection bores. Specifically, in the exemplary embodiment, electrical communications apparatus100includes a plurality of electrical modules132. Further, in the exemplary embodiment, electrical modules132are short form pluggable transceiver devices arranged to be selectively removable from electrical unit128. In alternative embodiments, electrical modules132include any electrical devices that enable electrical communications apparatus100to function as described herein. Electrical modules132each extend along the Z-axis from an external connection end108positioned exterior electrical unit128to pin end194(shown inFIG. 5) positioned within electrical unit128. External connection end108of electrical modules132define a bore thereon to facilitate electrically coupling an external communications line134. In the exemplary embodiment, external communication lines134include an optical fiber cable. In alternative embodiments, external communication lines134include any electrical connection units that enable electrical communications apparatus100to function as described herein.

FIG. 2is a perspective view of support structure102of electrical communications apparatus100shown inFIG. 1. In the exemplary embodiment, support structure102further includes a first interior sidewall136and a second interior sidewall138transversely spaced from first interior sidewall136. First interior sidewall136and second interior sidewall138each extend from module end106to external connection end108. Support structure102further includes a rear wall140positioned at external connection end108and extending between first interior sidewall136and second interior sidewall138. In alternative embodiments, external connection end108of support structure is open to the surrounding medium (e.g. air). A support surface142extends between first interior sidewall136and second interior sidewall138. First interior sidewall136, second interior sidewall138, rear wall140, and support surface142collectively define an interior space144of support structure102therebetween. Interior space144is accessible through open end112. Further, in the exemplary embodiment, a connection port146is defined within rear wall140and is arranged to facilitate electrical connection between electrical modules132received within electrical unit128and an external electrical device (not shown) when electrical housing104is received within support structure102.

In the exemplary embodiment, guide rails148are coupled to support surface142and are arranged to guide electrical housing104during an insertion of electrical housing104within interior space144. In particular, guide rails148extend along the Z-axis from an area adjacent open end112to an area adjacent external connection end108. In the exemplary embodiment, guide rails148form a track150arranged to receive a corresponding guide element (not shown) coupled respectively to first interior sidewall136and second interior sidewall138of electrical housing104.

In the exemplary embodiment, upper face110includes a C-bar152coupled to top surface118. In alternative embodiments, C-bar152is coupled to bottom surface120. In further alternative embodiments, C-bar152is coupled to support structure102in any manner that enables electrical communications apparatus100to function as described herein. C-bar152includes an upper lip154(shown inFIG. 4), a lower lip156and spine158extending between upper lip154and lower lip156. Upper lip154and lower lip156extend in parallel from spine158substantially along the Z-axis. Further, spine158is transversely oriented to upper lip154and lower lip156and extends substantially along the Y-axis between upper lip154and lower lip156. Thus, as best seen inFIG. 5, in the exemplary embodiment C-bar152has a substantially C shaped cross section along the Z-axis. In alternative embodiments, C-bar152has any shape that enables C bar to function as described herein. In even further alternative embodiments, C-bar152is a heat sink coupled adjacent electrical unit128. In the exemplary embodiment, C-bar152is unitarily formed as one piece. In alternative embodiments, lower lip156and upper lip154are detachably coupled to spine158. In further alternative embodiments, upper lip154, lower lip156and spine158are coupled in any matter that enables C-bar152to function as described herein.

As best seen inFIG. 4, in the exemplary embodiment, a flange160is fixedly coupled to C-bar152and extends along the Z axis within interior space144between first sidewall114and second sidewall116. Flange160includes a coupling end162coupled to C-bar152extends substantially in the Z-direction to a distal free end164. In particular, in the exemplary embodiment, flange160is coupled to lower lip156of C-bar152. In the exemplary embodiment, flange160includes a first surface166and a second surface168. Particularly, in the exemplary embodiment, first surface166is an upper flange surface and second surface168is a lower flange surface. In alternative embodiments, first surface166and second surface168may be oriented relative to one another in any manner that enables flange160to function as described herein.

Referring again toFIG. 2, in the exemplary embodiment, a support heat transfer member170(or alternatively top wedge) is coupled to flange160. Specifically, top wedge170extends within interior space144of support structure102from an area adjacent C-bar152in the Z-direction. In the exemplary embodiment, top wedge170is composed of a thermally conductive material. In particular, top wedge170is composed of an aluminum alloy. In alternative embodiments, top wedge170is composed of a copper alloy. In further alternative embodiments, top wedge170is composed of any material that enables electrical communications apparatus100to function as described herein.

In the exemplary embodiment, top wedge170comprises a support mounting face172(shown inFIG. 5) coupled to support structure102. Specifically, in the exemplary embodiment, support mounting face172is coupled to lower flange surface168(shown inFIG. 5). In alternative embodiments, a thermal gap pad (not shown) is coupled between support mounting face172and lower flange surface168. Top wedge170further includes a support coupling face174opposite support mounting face172. In the exemplary embodiment, support coupling face174is polished to facilitate greater thermal conductivity as will be described in greater detail below. In particular, in the exemplary embodiment, top wedge170has a tapered height (defined along the Y-axis) such that support coupling face174is tapered along the Z-axis. Specifically, in the exemplary embodiment, support coupling face174is tapered such that top wedge170extends a first height adjacent open end112and a second height adjacent flange160distal free end164, such that the second height is greater than the first height. In alternative embodiments, support coupling face174is tapered such that the first height is greater than the second height.

FIG. 3is a perspective view of electrical communications apparatus100shown inFIG. 1wherein the electrical housing104is partially removed from support structure102.

In the exemplary embodiment, electrical unit128extends within electrical housing104. In the exemplary embodiment, electrical unit128includes a conduction side176positioned adjacent module side130. In the exemplary embodiment, conduction side176is transversely oriented to module side130and extends in the Z direction from module side130. Conduction side176is arranged to facilitate thermal conduction of heat from electrical unit128to support structure102.

In the exemplary embodiment, a unit heat transfer member178(or alternatively bottom wedge) is coupled to conduction side176of electrical unit128. In particular, bottom wedge178substantially covers conduction side176of electrical unit128. Bottom wedge178is composed of generally the same material as top wedge170. That is, bottom wedge178is composed of a thermally conductive material to facilitate heat transfer from electrical unit128. Specifically, in the exemplary embodiment, bottom wedge178is composed of an aluminum alloy. In alternative embodiments, bottom wedge178is composed of any material that enables electrical communications apparatus100to function as described herein.

Bottom wedge178includes a unit mounting face180adjacent electrical unit128and a unit coupling face182opposite unit mounting face180. Top wedge170has a tapered height (defined along the Y-axis) such that height of unit coupling face182tapers in the Z-direction. Specifically, in the exemplary embodiment, bottom wedge178is tapered such that bottom wedge178extends a first height adjacent module side130and a second height adjacent a rear side184of electrical unit128, wherein the first height is greater than the second height. In alternative embodiments, unit coupling face182is tapered such that the first height is greater than the second height. In particular, bottom wedge178is tapered along unit coupling face182and top wedge170(shown inFIG. 2) is correspondingly tapered along support coupling face174to facilitate slidably coupling bottom wedge178to top wedge170. In other words, top wedge170and bottom wedge178have substantially equal and opposite tapered heights from one another such that the coupling faces174,182are in full contact with one another along the Z-direction and along the X-direction when electrical housing104is fully received within support structure102to facilitate maximal heat transfer between said coupling faces174,182. Specifically, as used herein, “full contact” refers to having as close to 100% as possible of the surface area of unit coupling face182being in contact with as close to 100% as possible of the surface area of support coupling face174. In alternative embodiments, coupling faces174,182are substantially in contact with one another along the Z-direction and along the X-direction when electrical housing104is fully received within support structure102. Specifically, as used herein, “substantially in contact” refers to having over a majority of the surface area of unit coupling face182being in contact with over a majority of the surface area of support coupling face174. In alternative embodiments, top wedge (shown inFIG. 2) and bottom wedge178are tapered in any manner that enables electrical communications apparatus100to function as described herein.

In the exemplary embodiment, a first thermal gap pad186is coupled to electrical unit128. Specifically, first thermal gap pad186is coupled between bottom wedge178and conduction side176of electrical unit128. First thermal gap pad186facilitates improved heat transfer between conduction side176of electrical unit128and bottom wedge178. For example, in the exemplary embodiment, conduction side176is not an entirely smooth surface. Thus, first thermal gap pad186facilitates improved thermal conduction of heat from conduction side176by flexibly filling air gaps in conduction side176when compressed. In the exemplary embodiment, first thermal gap pad186is partially composed of a resiliently flexible material and partially composed of a thermally conductive material. Specifically, in the exemplary embodiment, first thermal gap pad186is composed of a silicone substantially evenly dispersed with metal oxide particles. In alternative embodiments, first thermal gap pad186is composed of any material that enables first thermal gap pad186to function as described herein.

In the exemplary embodiment, first thermal gap pad186is arranged on conduction side176such that compression of first thermal gap pad186along the Y-axis substantially fills air gaps in conduction side176and compresses the metal oxide particles within first thermal gap pad186to contact one another, thereby forming a thermal conduction bridge within first thermal gap pad186to facilitate heat conduction through first thermal gap pad186. Specifically, in the exemplary embodiment, around 30% compression of first thermal gap pad186along the Y-axis is sufficient to facilitate heat conduction through first thermal gap pad186. In alternative embodiments, first thermal gap pad186is arranged such that any compression is sufficient to facilitate heat conduction that enables electrical communications apparatus100to function as described herein. In further alternative embodiments, bottom wedge178is directly coupled to conduction side176of electrical unit128without a thermal gap pad positioned therebetween. In further alternative embodiments, bottom wedge178is unitarily formed with electrical unit128such that no thermal gap pad is necessary to facilitate efficient heat conduction into bottom wedge178.

FIG. 4is a perspective view of electrical communications apparatus100shown inFIG. 1with portions of support structure102removed to reveal internal construction of electrical housing104.FIG. 5is a cross sectional view of a portion of electrical communications apparatus100ofFIG. 4taken along the line5-5.FIG. 6is an exploded perspective view of electrical communications apparatus100ofFIG. 1with portions of electrical housing104removed and support structure102removed to reveal internal construction.

Referring toFIG. 5, in the exemplary embodiment, an axis188is shown extending from lower lip156of C-bar152in the Z direction. In particular, in the exemplary embodiment flange160is oriented at an acute angle θ to axis. In the exemplary embodiment, flange160is oriented at such an angle that flange160generally extends partially downward towards distal free end164. Further, in the exemplary embodiment, flange160is resiliently biased at angle θ. Thus, when electrical housing104is inserted into support structure102, top wedge170frictionally engages bottom wedge178at respective coupling faces174,182, and further compressing first thermal gap pad186to facilitate efficient thermal conduction between electrical unit128and support structure102. In particular, in the exemplary embodiment, substantially all surface area of coupling faces174,182contact one another to maximize thermal conduction between bottom wedge178and top wedge170.

In the exemplary embodiment, electrical housing104is locked into support structure102via a locking mechanism (not shown) such that electrical housing104resists movement in the Z-direction. Force arrows202show translation of a downward force applied by flange160through top wedge170, bottom wedge178and into first thermal gap pad186. In particular, downward force is applied on electrical unit128by top wedge170in a direction normal to coupling face174of top wedge170. Additionally, frictional engagement between top wedge170and bottom wedge178facilitates downward force translation through between top wedge170and bottom wedge178. As shown inFIGS. 4 and 5, translation of downward force applied by top wedge170compresses first thermal gap pad186approximately 30%. In other words, in the exemplary embodiment, first thermal gap pad186has a height 70% of its total resting height when electrical unit128is removed from electrical housing104. Compression of first thermal gap pad186enables metal oxide particles within first thermal gap pad186to come into contact with one another to permit thermal conduction through first thermal gap pad186.

In the exemplary embodiment, electrical housing104includes a carrier190spanning a lower surface204of electrical housing104. Specifically, in the exemplary embodiment, carrier190is a printed circuit board. Further, electrical unit128includes a plurality of electrical connectors192positioned within each bore of electrical unit128. Electrical connectors192are arranged in electrical communication with electrical elements of printed circuit board190such that when electrical modules132are inserted into electrical unit128, a pin end194of each electrical module is aligned to form an electrical connection with electrical connectors192.

In the exemplary embodiment, electrical unit128further includes a connection side196transversely oriented to module side130and positioned adjacent printed circuit board190. Connection side196is arranged to facilitate electrical communication between electrical modules132and printed circuit board190. In the exemplary embodiment, connection side196is composed of a thermally conductive material to permit heat transfer from electrical modules132positioned within electrical unit128to connection side196. Specifically, connection side196is composed of an aluminum alloy. In alternative embodiments, connection side196is composed of any material that enables electrical communications apparatus100to function as described herein. Further, in the exemplary embodiment, a second thermal gap pad198is positioned between connection side196and printed circuit board190to facilitate heat transfer between connection side196of electrical unit128and support structure102through printed circuit board190. For example, as will be described in greater detail with respect toFIGS. 7 and 8, in the exemplary embodiment, printed circuit board190includes a conductive weave extending therethrough and arranged to contact second thermal gap pad198and support structure102to facilitate conductive heat transfer through printed circuit board190.

In the exemplary embodiment, electrical housing104includes external connectors200positioned adjacent external connection end108of support structure102when electrical housing104is received within support structure102. External connectors200are electrically coupled to printed circuit board190such that electrical modules132are operable to be in electrical communication with external connectors200through a conductive pathway (not shown) extending through printed circuit board190.

Electrical housing104is substantially composed of a thermally conductive material substantially similar to top wedge170and bottom wedge178. Further, thermally conductive regions of electrical housing104are arranged to substantially contact surface regions of electrical modules132when electrical modules132are received within electrical housing104. Specifically, in the exemplary embodiment, electrical housing104is substantially composed of an aluminum alloy. In alternative embodiments, electrical housing104is composed of any thermally conductive material that enables electrical communications apparatus100to function as described herein.

FIG. 7is a schematic side view of printed circuit board190for use in the exemplary electrical communications apparatus.

In the exemplary embodiment, connection side196of electrical unit128is coupled to second thermal gap pad198. In the exemplary embodiment, second thermal gap pad198has substantially the same material composition as first thermal gap pad186(shown inFIG. 5). That is, in the exemplary embodiment, second thermal gap pad198is partially composed of a resiliently flexible material and partially composed of a thermally conductive material. Specifically, second thermal gap pad198is composed of a silicone substantially evenly dispersed with metal oxide particles. In the exemplary embodiment, when electrical housing104is received within support structure102, downward force (shown inFIG. 5) is translated through electrical unit128to compress second thermal gap pad198into a compressed state. In particular, in the exemplary embodiment, second thermal gap pad198is compressed approximately 30% in the Y-direction to facilitate thermal conduction via metal oxide particles within second thermal gap pad198.

In the exemplary embodiment, printed circuit board190includes a first thermal layer206coupled to second thermal gap pad198and arranged to thermally conduct heat from electrical unit128through second thermal gap pad198when second thermal gap pad198is in a compression state. In addition, in the exemplary embodiment, printed circuit board190includes a second thermal layer208vertically displaced from first thermal layer206. In the exemplary embodiment, first thermal layer206and second thermal layer208are copper plates. First thermal layer206and second thermal layer208respectively define an uppermost210and lowermost region212of printed circuit board190. In alternative embodiments, first thermal layer206and second thermal layer208are composed of any thermally conductive material that enables electrical communications apparatus100to function as described herein.

In the exemplary embodiment, printed circuit board190is predominantly composed of a non-thermally conductive circuit board material214. In the exemplary embodiment, circuit board material214is a dielectric material. In particular, circuit board material214is fiberglass. Circuit board material214is respectively coupled to first thermal layer206and second thermal layer208. In alternative embodiments, circuit board material214includes any material that enables electrical communications apparatus100to function as described herein.

In the exemplary embodiment, printed circuit board190includes an intermediary conductive layer216positioned within circuit board material214. Intermediary layer216divides printed circuit board material214into a first layer218, positioned in above intermediary layer216in the exemplary embodiment, and a second layer220positioned below intermediary layer216. In the exemplary embodiment, intermediary layer216is formed of copper. In alternative embodiments, intermediary layer216is formed of any material that enables printed circuit board190to function as described herein. In the exemplary embodiment, intermediary layer216is a grounding layer. In alternative embodiments, printed circuit board190does not include an intermediary layer. In further alternative embodiments, printed circuit board190includes any number of intermediary layers that enables electrical communications apparatus100to function as described herein.

In the exemplary embodiment, printed circuit board190defines a plurality of channels222extending within printed circuit board material214between first thermal layer206and second thermal layer208. In particular, in the exemplary embodiment, the plurality of channels222are vertical interconnect accesses (or alternatively VIAs). In the exemplary embodiment, VIAs222include a tubular conductive plating lining a circumference defined by VIAs222and positioned within through-holes (not shown) defined in printed circuit board190. Through holes are defined to extend unbroken vertically between first thermal layer206and second thermal layer208. In alternative embodiments, blind VIAs222are defined to extend through printed circuit board material214in horizontally displaced segments while maintaining thermal communication between segmented blinds through intermediary layers. In further alternative embodiments, printed circuit board190defines both blind VIAs and through hole VIAs. In even further alternative embodiments, VIAs222are defined in any arrangement that enables electrical communications apparatus100to function as described herein.

As shown inFIG. 7, in the exemplary embodiment, second thermal layer208is coupled to a third thermal gap pad199. In the exemplary embodiment, third thermal gap pad199has substantially the same material composition as first thermal gap pad186(shown inFIG. 5). That is, in the exemplary embodiment, third thermal gap pad199is partially composed of a resiliently flexible material and partially composed of a thermally conductive material. Specifically, third thermal gap pad199is composed of a silicone substantially evenly dispersed with metal oxide particles. In the exemplary embodiment, when electrical housing104is received within support structure102, downward force (shown inFIG. 5) is translated through electrical unit128to compress second thermal gap pad198into a compressed state. Downward force (shown inFIG. 5) is further translated through printed circuit board190to compress third thermal gap pad199into a compressed state. In particular, in the exemplary embodiment, third thermal gap pad199is compressed approximately 30% in the Y-direction to facilitate thermal conduction via metal oxide particles within third thermal gap pad199. In alternative embodiments, second thermal layer208is directly coupled to any material that facilitates conductive heat transfer between second thermal layer208and support structure102as described herein.

In the exemplary embodiment, third thermal gap pad199is further coupled to a thermal mount224. Thermal mount224is further coupled to support structure102. Thermal mount224is composed of a thermally conductive material arranged to approximately uniformly contact third thermal gap pad199in order to facilitate thermal conduction between third thermal gap pad199and thermal mount224. Specifically, in the exemplary embodiment, thermal mount224is composed of aluminum. In alternative embodiments, thermal mount224is composed of any thermally conductive material that enables electrical communications apparatus100to function as described herein.

Referring toFIGS. 5 and 7, during operation of electrical communications apparatus100heat generated by electrical modules132is thermally conducted into electrical housing104. Thus, in the exemplary embodiment, electrical communications apparatus100provides a thermal conduction path from electrical modules132to support structure102through top wedge170. Further, electrical communications apparatus100provides a thermal conduction path from electrical modules132to support structure102through first thermal layer206, VIAs, and second thermal layer208respectively. That is, in the exemplary embodiment, electrical communications apparatus100provides a thermal conduction path to conduct heat from the conduction side176of electrical unit128and connection side196of electrical unit128. In alternative embodiments, electrical communications apparatus100provides only a thermal conduction path to conduct heat from conduction side176of electrical unit128.

FIG. 8is a perspective view of an alternative support structure102for use in electrical communications apparatus100. In particular, in the exemplary embodiment, electrical communications apparatus100includes an engagement mechanism226coupled to flange160and arranged to selectively position top wedge170relative to bottom wedge178. In the exemplary embodiment, flange160is oriented to extend substantially parallel with lower lip156of C-bar152. In the exemplary embodiment, flange160defines a flange track228extending therethrough. A region of top wedge230extends generally through flange track228and defines a top wedge bore for receiving engagement mechanism226. Engagement mechanism226further extends through an additional bore defined in distal free end164of flange160. Thus, in the exemplary embodiment, when electrical unit128is received within electrical support structure102, rotation of engagement mechanism226in a first direction drives a lateral movement of top wedge170along track150in the Z direction away from contacting bottom wedge178. Further, rotation of engagement mechanism226in a second direction opposite the first direction drives a lateral movement of top wedge170along track150in the Z direction towards contacting bottom wedge178.

In the exemplary embodiment, engagement mechanism226includes a screw232coupled to a thumb nut234. In the exemplary embodiment, thumb nut234is coupled to region of top wedge230and positioned adjacent top wedge170. In alternative embodiments, thumb nut234extends through C-bar152such that thumb nut234is externally accessible by an operator. In further alternative embodiments, screw232includes a biasing member (not shown) arranged to bias screw232towards a lateral positioning of top wedge170. In further alternative embodiments, engagement mechanism226comprises any engagement mechanism226that enables electrical communications apparatus100to function as described herein.

In the exemplary embodiment, insertion of electrical housing104within support structure102is accomplished without frictionally engaging top wedge170and bottom wedge178. That is, before insertion of electrical housing104, engagement mechanism226is in a first position (not shown) defined by top wedge170being rearwardly positioned along the Z-axis such that when electrical unit128is received within support structure102, top wedge170does not contact bottom wedge178. Thus, when electrical housing104is inserted into support structure102, top wedge170is laterally displaced from bottom wedge178. An operator, then rotates engagement mechanism226in the second direction to drive lateral movement of top wedge170along track150in the Z direction towards contacting bottom wedge178. In particular, engagement mechanism226is rotated such that top wedge170contacts and applies a compression force on bottom wedge178. As a result, in the exemplary embodiment, compression applied by top wedge170is selectively variable by an operator. In alternative embodiments, compression force is applied to bottom wedge178in any manner that enables electrical communications apparatus100to function as described herein. Similarly, in the exemplary embodiment, when electrical housing104is removed from support structure102, an operator rotates engagement mechanism226in the first direction to drive lateral movement of top wedge170along track150in the Z direction away from contacting bottom wedge178. In alternative embodiments, compression force is applied to bottom wedge178in any manner that enables electrical communications apparatus100to function as described herein.

An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) improved cooling of electrical modules; (b) improved cooling of electrical units arranged to receive electrical units in a stacked configuration; (c) improved data throughput capabilities for electrical units; and (d) potential to be used with electrical housings having varied form factor through use of a fastening mechanism.

Exemplary embodiments of systems and methods for passive cooling of components within electrical devices are described above in detail. The systems and methods are not limited to the specific embodiments described herein but, rather, components of the electrical communications apparatuses and/or operations of the methods may be utilized independently and separately from other components and/or operations described herein. Further, the described components and/or operations may also be defined in, or used in combination with, other systems, methods, and/or devices, and are not limited to practice with only the electrical communications systems and apparatuses described herein.