Abstract:
An electronic module is employed with at least one interiorly positioned fastener that at least partially secures a central region of the electronic module to an object to prevent bowing or warping. The module contains a base, at least two peripheral fasteners at opposed ends of the module, and the at least one interiorly positioned fastener, wherein the base is capable of accepting electronic components and further includes at least one layer, and wherein the at least one interiorly positioned fastener is interposed between the at least two peripheral fasteners.

Description:
TECHNICAL FIELD 
       [0001]    The invention described herein relates generally to electronic modules that utilize at least one center mounting fastener. 
       BACKGROUND OF THE INVENTION 
       [0002]    Electronic modules are basically self-contained functional units that are used to create a larger system. Electronic modules may be situated on a separate base or portion to allow a user to systematically test for error, quickly replace a failed module, and in this particular case, effectively dissipate heat. The bottom-most portion of an electronic module may be comprised of a material that quickly dissipates or collects heat in order to divert it away from the electronic modules, which are the source of the heat. This heat dissipating component of the electronic module is preferably metallic in nature. The greater the surface area of the metallic component of the electronic module, the faster it can dissipate heat. However, certain applications require modules that are only capable of housing a few components. In those situations, not only is the dispersion of heat required, but the dispersion must be highly efficient or at least capable of diverting the heat without damage to the components. In certain applications, hundreds of Amps of electricity may pass through an electric component and if not cooled, can reach a temperature of about ninety (90) degrees Celsius, a temperature close to the degradation temperature of the electronics in the module. In these cases, the base of the module must be extremely efficient at dissipating heat in order for the electronic components not to prematurely fail or burn out. Moreover, this dissipation of heat allows the components to function properly. 
         [0003]    Existing electronic modules are attached to a variety of devices, such as printed circuit boards (PCBs), housings, objects, etc., usually by screws, typically positioned at the corners of the electronic module. If the electronic modules produce a large amount of heat, the electronic modules are placed on and in contact with heat sinks, which assist the electronic module in the dispersion of the heat. Moreover, when electronic modules become hot due to the heat created by the components, the electronic modules tend to bow and bend creating a gap between the electronic module and the object it is resting on, as shown, but not drawn to scale, in  FIG. 6 . This gap may be a small numeric value, but in certain instances, this gap can cause hot spots to form on the electronic module. These hot spots, if not alleviated quickly, may have negative consequences such as burning out or premature failure of the electronic components. 
         [0004]    Larger and thicker electronic modules are able to quickly and more efficiently dissipate heat created by components. However, while larger and thicker electronic modules may be more desirable, certain devices and applications may require smaller and thinner electronic modules because of space restraints. Smaller and thinner electronic modules will begin to bow at a smaller change in temperature when compared to a larger and thicker electronic module. This means that smaller and thinner electronic modules will begin to bow sooner, thereby creating hot spots, at a earlier time than larger and thicker electronic modules under the same circumstances and environment. 
         [0005]    Another factor of electronic module bowing is the inherent nature of electronic module manufacturing. Electronic modules are not manufactured perfectly level or even, thereby creating a “bowed” electronic module. When these “bowed” modules are placed on a heat sink, an initial gap is formed between the module and the heat sink. Currently, conventional methods of securing an electronic module to a heat sink do not reduce the gap created between the module and the heat sink. Moreover, when a module is secured to a heat sink by fasteners, the clamping force created by each fastener may not be equal, creating asymmetrical clamping forces throughout the module. This uneven distribution of clamping forces causes the electronic module to bow, thereby diminishing the surface area of the module that contacts the heat sink. This reduction in contact surface area decreases the amount of heat that flows from the electronic module to the heat sink, and in so doing, overheating components that are attached to the module. 
         [0006]    As stated above, this bow or gap that is created decreases the amount of heat that is dissipated from components in the region of bowing or phrased alternatively, where the contacting engagement is with less force, which then overheats. Moreover, certain materials tend to bow quicker than other materials because of their innate properties, particularly attributable to their thermal expansion coefficient. Depending on the material&#39;s thermal expansion coefficient, the material may bow faster or slower than a material that has a different thermal expansion coefficient. Nevertheless, manufacturing processes, asymmetrical clamping forces, the quantity, position on the electronic module, and surrounding temperature of components on an electronic module greatly affect the characteristics and rate at which the electronic module bows. Therefore, what is needed is an electronic module that may utilize at least one center mounting fastener in an interior region of the module in order to more effectively dissipate the heat created by components by maintaining forceful contiguous contact with an underlying heat sink. 
         [0007]    Further limitations and disadvantages of conventional, traditional, and proposed approaches will become apparent to one of skill in the art, through comparison of such systems and methods with certain embodiments the claimed invention as set forth in the remainder of the present application with reference to the drawings. 
       SUMMARY OF THE INVENTION 
       [0008]    In one embodiment of the invention an electronic module is employed with at least one interiorly positioned fastener that at least partially secures a central region of the electronic module to an object to prevent bowing or warping. The module contains a base, at least two peripheral fasteners at opposed ends of the module, and the at least one interiorly positioned fastener, wherein the base is capable of accepting electronic components and further includes at least one layer, and wherein the at least one interiorly positioned fastener is interposed between the at least two peripheral fasteners. 
         [0009]    In another embodiment of the invention an electronic module is employed with at least one interiorly positioned fastener that at least partially secures a central region of the electronic module to a heat sink to prevent bowing or warping. The module contains a base, at least two peripheral fasteners at opposed ends of the module, and the at least one interiorly positioned fastener, wherein the base is capable of accepting electronic components. The base includes at least one layer, and optionally more than one layer, e.g., three or more layers. When the base has three layers, it preferably includes a first metallic layer, an intermediary dielectric layer, and a third metallic layer, wherein the first metallic layer further comprises a peripheral outer edge, wherein the peripheral outer edge is at least a minimum distance from sides of the third layer to create a non-conductive zone, and wherein the at least one interiorly positioned fastener is interposed between the at least two peripheral fasteners and interiorly of the first metallic layer. 
         [0010]    In yet another embodiment of the invention an electronic module contains a base, at least two peripheral fasteners, and the at least one interiorly positioned fastener, means for selecting a location for the at least one interiorly positioned fastener that at least partially secures a central region of the electronic module to an object to prevent bowing or warping a base, means for attaching electronic components to the base, and wherein the base further includes at least one layer, means for securing the electronic module to the object. 
         [0011]    In still another embodiment of the invention an electronic module is employed with at least one interiorly positioned fastener that at least partially secures a central region of the electronic module to an object to prevent bowing or warping. The module contains a base and the at least one interiorly positioned fastener, wherein the base is capable of accepting electronic components and further includes at least one layer, and wherein the at least one interiorly positioned fastener is interposed between the at least two peripheral fasteners. 
         [0012]    These and other advantages and novel features of the claimed invention, as well as details of illustrated embodiments thereof, will be more fully understood from the following description and drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  illustrates a top elevational view of an embodiment of a module with at least one center mounting aperture (two apertures being illustrated in the figure); 
           [0014]      FIG. 2  illustrates a side perspective view of  FIG. 1 ; 
           [0015]      FIG. 3  illustrates a bottom elevational view of  FIG. 1 ; 
           [0016]      FIG. 4  illustrates a top elevational view of another embodiment of a module with at least one center mounting aperture (two apertures being illustrated in the figure); 
           [0017]      FIG. 5  illustrates a side perspective view of  FIG. 4 ; 
           [0018]      FIG. 6  illustrates a side perspective view of a stylized depiction of a “bowed” module of  FIG. 4 , not shown to scale; 
           [0019]      FIG. 7  illustrates a bottom elevational view of  FIG. 4 ; 
           [0020]      FIG. 8  illustrates a top elevational view of another embodiment of a module with at least one offset center mounting aperture (two apertures being illustrated in the figure); 
           [0021]      FIG. 9  illustrates a top elevational view of another embodiment of a module with at least one center mounting aperture (two apertures being illustrated in the figure); and 
           [0022]      FIG. 10  illustrates a top elevational view of another embodiment of a module with one center mounting aperture. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    The best mode for carrying out the invention will now be described for the purposes of illustrating the best mode known to the applicant at the time. The examples are illustrative only and not meant to limit the invention, as measured by the scope and spirit of the claims. 
         [0024]    The term “bowing” as used herein means the curvature of a substrate about a median plane. The term “warping” as used herein means the linear displacement of the surface of a substrate with respect to a line defined by the center of the substrate. 
         [0025]    Generally, thermal expansion is the increase in volume of a material as temperature increases. As long as the pressure remains constant, whenever there is a change in temperature, a material&#39;s size and dimension will change accordingly. The coefficient of thermal expansion describes how the size of an object changes with a change in temperature. Specifically, it measures the fractional change in volume per degree change in temperature at a constant pressure. These measurements can also be calculated using equations that take in consideration the object&#39;s length, the change in temperature, the material&#39;s coefficient of thermal expansion, etc. As such, there are many existing equations that pertain to a material&#39;s thermal expansion, the more commonly used equations being related to the material&#39;s length, area, and volume. Though there are multiple complex variations of such equations, provided below are a few equations in a simpler form for illustrative purposes and not for limiting the invention. 
         [0026]    Without being held to any one theory or mode of operation, it is believed that, as shown in Table 1, bowing may be caused by thermal expansion or imparted by a manufacturing process and has a detrimental effect on electronic components. As a “bowed” module, the module is disengaged (or alternatively, secured to the heat sink with less force) from the heat sink, it thereby retains more of its heat. Heat is generated by electronic components and if the module cannot dissipate the generated heat, components themselves will overheat and perhaps become damaged. Table 1 shows a “before” and “after” set of temperatures that were measured across components on multiple examples of three layer modules, with and without center fasteners in the circuit boards. Different thermally conductive materials were also used during the experiment. The examples described as “Prior Art” were designed without the implementation of center fasteners, while the examples designated as “Invention” utilized center fasteners. As shown, diodes operating on modules with center fasteners have lower operating temperatures than diodes operating on modules without center fasteners, at times lowering the temperature of the diode by thirty five (35) degrees Celsius or more.  FIG. 10  illustrates electronic module  100  with heat generating electronic components  50 ,  52 , and  54 , wherein component  50  represents Component A in Table 1, wherein component  52  represents Component B in Table 1, and wherein component  54  represents Component C in Table 1. 
         [0000]    
       
         
               
             
               
               
               
               
               
               
               
               
               
               
               
             
               
               
               
               
               
               
               
               
               
               
               
             
           
               
                 TABLE 1 
               
             
             
               
                   
               
               
                 Temperature Differences Between Components on Modules With and Without Center Fasteners 
               
             
          
           
               
                   
                   
                   
                   
                   
                   
                 Thermally 
                   
                   
                   
                   
               
               
                   
                   
                   
                   
                   
                 Thermally 
                 Conductive 
                 Run 
                 Component 
                 Component 
                 Component 
               
               
                   
                 Input 
                 Output 
                 Output 
                 Output 
                 Conductive 
                 Material 
                 Time 
                 A 
                 B 
                 C 
               
               
                 Module 
                 Amps 
                 Amps 
                 Volts 
                 Watts 
                 Material 
                 Thickness 
                 (Min.) 
                 (° C.) 
                 (° C.) 
                 (° C.) 
               
               
                   
               
             
          
           
               
                 Invention 
                 230 
                 98.8 
                 1.07 
                 105.72 
                 Dow* 340 
                 5 mil 
                 30 
                 29.2 
                 30.6 
                 30.8 
               
               
                 (A) 
               
               
                 Prior Art 
                 230 
                 99.9 
                 1.04 
                 103.9 
                 Dow* 340 
                 5 mil 
                 30 
                 49.1 
                 46.7 
                 34.4 
               
               
                 (A′) 
               
               
                 Invention 
                 230 
                 100.6 
                 1.02 
                 102.61 
                 Dow* 340 
                 2 mil 
                 30 
                 28.3 
                 29.2 
                 29.3 
               
               
                 (B) 
               
               
                 Prior Art 
                 230 
                 100.2 
                 1.078 
                 108.02 
                 Dow* 340 
                 2 mil 
                 30 
                 63.4 
                 61.3 
                 43.3 
               
               
                 (B′) 
               
               
                 Invention 
                 230 
                 96.7 
                 1.065 
                 102.99 
                 Burndy ® 
                 5 mil 
                 30 
                 30.3 
                 31.8 
                 31.8 
               
               
                 (C) 
                   
                   
                   
                   
                 Penetrox 
               
               
                 Prior Art 
                 230 
                 98.5 
                 1.04 
                 102.44 
                 Burndy ® 
                 5 mil 
                 30 
                 41.9 
                 41.6 
                 35.9 
               
               
                 (C′) 
                   
                   
                   
                   
                 Penetrox 
               
               
                 Invention 
                 230 
                 98.7 
                 1.073 
                 104.94 
                 Dow* TC- 
                 5 mil 
                 30 
                 37.5 
                 37.9 
                 38.1 
               
               
                 (D) 
                   
                   
                   
                   
                 5121 
               
               
                 Prior Art 
                 230 
                 98.9 
                 1.06 
                 104.83 
                 Dow* TC- 
                 5 mil 
                 30 
                 48.2 
                 47.1 
                 41.8 
               
               
                 (D′) 
                   
                   
                   
                   
                 5121 
               
               
                 Invention 
                 230 
                 98.5 
                 1.078 
                 106.18 
                 Dow* TC- 
                 5 mil 
                 30 
                 29 
                 29.5 
                 29.2 
               
               
                 (E) 
                   
                   
                   
                   
                 5022 
               
               
                 Prior Art 
                 230 
                 97.3 
                 1.066 
                 103.72 
                 Dow* TC- 
                 5 mil 
                 30 
                 34.1 
                 35.8 
                 31.5 
               
               
                 (E′) 
                   
                   
                   
                   
                 5022 
               
               
                   
               
               
                 *Dow represents Dow Corning ® 
               
             
          
         
       
     
         [0027]      FIGS. 1 through 3  illustrate multiple views of an embodiment of the invention, namely, electronic module  10  which includes base  16 , at least two peripheral fasteners  12  (four apertures illustrated in the figures), and at least one central fastener (two central fasteners  14 A and  14 B illustrated). Depending on the size of base  16 , more or less central fasteners  14 A and/or  14 B and peripherally-positioned fasteners  12  may be utilized. It is recognized that fasteners  12  may also be positioned parallel to, and interiorly of any of sides  20 ,  22 ,  24  or  26 , and located at a corner or along an edge of electronic module  10 . It is also recognized that electronic module  10  may be fastened to an object utilizing the at least one central fastener  14 A and/or  14 B, without the inclusion of the at least two peripheral fasteners  12  although not preferred. The number of non-interior fasteners is typically at least two, and may increase to eight or more, depending on the needs of the application. Base  16  is made of a material, preferably metallic, that dissipates heat such as copper, tin, or aluminum and alloys thereof. Base  16  may also include multiple layers and have first side  20 , second side  22 , third side  24 , and fourth side  26 .  FIG. 2  shows an embodiment of the invention that may include base  16  having two layers, first top layer  18  and second bottom layer  19 . First layer  18  may be an insulating layer that does not substantially conduct electricity, while second layer  19  is typically a metallic material that dissipates heat, such as copper, tin, and aluminum or alloys thereof. 
         [0028]    With continued reference to  FIGS. 1 through 3 , the at least one central fastener  14 A and/or  14 B is located within central region  46  of electronic module  10 . Central region  46  may include the area interposed between the at least two peripherally-positioned fasteners  12  or between tangential lines  44 , which are perpendicular to sides  22  and  26  and tangent to the innermost circumferential edge of each of peripheral fasteners  12 . Tangential lines  44  may also be perpendicular to sides  22  and  26  and tangent to the innermost circumferential edge of the innermost peripheral fastener  12  of sides  20  and  24 .  FIG. 9  illustrates central region  46  as being defined by inner region perimeter  48  that outlines components  28 . Inner region perimeter  48  may also be tangential to components  28 , nearly contacting the outermost point of components  28 . The shape of inner region perimeter  48  may be an eclipse as shown in  FIG. 9 , but the shape may also be circular, square, rectangular, or oblong in shape. 
         [0029]      FIGS. 4 through 7  shows another embodiment of the claimed invention that may include base  16  as having three layers, first layer  30 , intermediary layer  32 , and third layer  34 , as shown in  FIG. 5 , the thickness of each being chosen using sound engineering, and which thickness may be the same or different as illustrated in  FIG. 5 . First and third layer  30  and  34  may be made of a heat dissipating material, preferably a conductive metal, while intermediary layer  32  is a dielectric layer made of a ceramic material that is both thermally conductive and electrically insulting, non-limiting examples of which include Bergquist® Thermal Clad®. If, however, components  28  have their contact leads on their bottom-most surface, thereby “shorting” components  28 , base  16  may include another insulating layer between components  28  and first layer  30 . Base  16  is capable of accepting and housing components  28 , such as diodes, transistors, semi-conductor chips, or any other type of components one of ordinary skill in the art may realize. Components  28  are attached to base  16  with solder, which is also a thermal conductive material that can dissipate heat quickly and efficiently. Base  16  dissipates the heat that is generated by components  28  when an electric current passes through components  28 . 
         [0030]    The at least two peripheral fasteners  12  and the at least one central fastener  14 A and/or  14 B fasten electronic module  10  to an object or article that may include a printed circuit board (PCB), a housing, a container, a device, or any other object that may be realized by persons of ordinary skill in the art that may utilize an electronic module. When attaching the electronic module  10  to a PCB, the electronic module  10  is mounted onto heat sink  38 , as shown in  FIG. 5 , to most effectively dissipate generated heat. Heat sinks  38  are also made of a metallic material that can quickly dissipate heat, such as copper, aluminum, and tin and alloys thereof. Electronic module  10  is joined, permanently or temporarily, to heat sink  38  with a thermally conductive compound, non-limiting examples of which include Dow Corning® 340 Heat Sink Compound, Dow Corning® TC-5121, Indium 14993 Y, 99.9% Indium-Waffle Cut, or Burndy® Penetrox Heat Sink Grease. This thermally conductive compound facilitates the exchange of heat between electric module  10  and heat sink  38 . 
         [0031]    The at least two peripheral fasteners  12  and the at least one central fastener  14 A and/or  14 B may be fastened to an object or article by holes and screws, clips, snap-on&#39;s, hooks and loops, nails, nuts and bolts, rivets, or any other fasteners that may be realized by persons of ordinary skill in the art that may securely fasten electronic module  10  to the object, article, or heat sink. The diameter of the at least two peripheral fasteners  12  and the at least one central fastener  14 A and/or  14 B may be substantially equal, or may be independently different. In one aspect of the invention, the at least two peripheral fasteners  12  and the at least one central fastener  14 A and/or  14 B are torqued to a pressure of about fifty (50) inch/pounds, with a variable range of about two (2) inch/pounds, onto electronic module  10 . This range in pressure from forty-eight to fifty-two (48-52) inch/pounds allows electronic module  10  to be sufficiently in contact with an object, such as a heat sink. The uniform amount of pressure created by the at least two peripheral fasteners  12  and the at least one central fastener  14 A and/or  14 B allows for maximum contiguous contact between the adjacent surfaces of electronic module  10  and heat sink  38 . The more surface area of electronic module  10  that comes into contact with a heat sink and/or thermally conductive compound, the more efficient heat is dissipated from components  28  and localized hot spots are minimized. Moreover, in order for electronic module  10  to be properly mounted onto a heat sink, the heat sink has corresponding peripheral and central fasteners, such as an internally threaded hole if the at least one central fastener  14 A and/or  14 B is a threaded hole and mating screw. 
         [0032]    With continued reference to  FIGS. 4 through 7  just as first and third layer  30  and  34  are separated by a dielectric layer  32  to create electrical isolation, first layer  30  is also set apart from the at least two peripheral fasteners  12 , the at least one central fastener  14 A and/or  14 B, and/or the sides  20 ,  22 ,  24  or  26 , to create electrical isolation, as shown in  FIGS. 4 and 5 . The minimum distance between first layer  30  and the at least two peripheral fasteners  12 , the at least one central fastener  14 A and/or  14 B, and/or the sides  20 ,  22 ,  24  or  26  depends on a variety of factors, one being the working voltage that is used by electronic module  10 . The corresponding minimum distances with respect to the working voltage used is defined by the International Electrotechnical Commission (IEC) reference, particularly IEC 60974-1, which is a standard relied upon by the industry. Voltage specifications are dependent on the application of a device and other properties such as maximum thresholds of an electronic component. The minimum distance between first layer  30  and the at least two peripheral fasteners  12 , the at least one central fastener  14 A and/or  14 B, and/or the sides  20 ,  22 ,  24  or  26  may also be increased to accommodate other factors such as ease of manufacturing. In an embodiment of the claimed invention, a voltage range of about forty (40) to nine hundred (900) Volts may be utilized. 
         [0033]    The area between outer edge  40 , of first layer  30 , and sides  20 ,  22 ,  24 , and  26  and the at least two peripheral fasteners  12  is a non-conductive zone  42  that also electrically isolates first layer  30  and third layer  34 . This electrical isolation decreases the chances of creating a potential between the layers. If the distance between first layer  30  and the at least two peripheral fasteners  12 , the at least one central fastener  14 A and/or  14 B, and/or the sides  20 ,  22 ,  24  or  26  is not large enough, a potential is created and will act as a connection between the two layers, thereby creating a “short” between first layer  30  and third layer  34 . Unless intentional, creating a potential or connection between two layers that are meant to be separate may cause certain connections to “short” and function improperly. The distance between first layer  30  and the at least two peripheral fasteners  12 , the at least one central fastener  14 A and/or  14 B, and the sides  20 ,  22 ,  24  or  26  is determined by sound engineering and in conjunction with reference to IEC 60974-1 to prevent conductive metallic layers from “connecting” to one another. 
         [0034]    The portion or area as described by first layer  30  is the interior region of electronic module  10  in which the at least one central fastener  14 A and/or  14 B may be located. The at least one central fastener  14 A and/or  14 B may be located anywhere within this interior region to secure electronic module  10  to an object, such as heat sink  38 . Components  28  are also located within this interior region of electronic module  10  in order to prevent a “short” from occurring between itself and an electrically conductive material, such as copper. The distance between components  28  and the boundaries and perimeter of the interior region of the electronic module  10  is determined by sound engineering to prevent components  28  from “shorting” or from creating an undesirable connection. 
         [0035]    The at least one central fastener  14 A and/or  14 B is located in the interior region of electronic module  10  and base  16 . The interior region of base  16  is also located interiorly of first side  20 , second side  22 , third side  24 , and fourth side  26 . In one embodiment of the invention, the at least one central fastener  14 A and/or  14 B may be located at a point near the center, intersecting the midpoint of each side of base  16 . The point near the center of base  26  may be substantially equidistant from first side  20  and third side  24 , and substantially equidistant from second side  22  and fourth side  26 . In another embodiment of the invention, wherein the at least one central fastener  14 A and/or  14 B are two central fasteners, these fasteners may be positioned in a spread apart in an offset manner but positioned interiorly of each peripheral edge, as shown in  FIG. 8 . The location of the at least one central fastener  14 A and/or  14 B within the interior region of base  16  is selected by sound engineering, taking into consideration the number of components  28 , amount of current delivered to components  28 , manufacturer specifications regarding components  28 , and etc. 
         [0036]    While the invention has been described with reference to certain embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from its scope. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed, but that the invention will include all embodiments falling within the scope of the appended claims.