Abstract:
A thermally-insulative insert device and method of use of same is disclosed. Specifically, the thermally-insulative insert device, comprising internal and external threads, allows attachment of an assembled part to a heat source while reducing heat transfer between the assembled part and the heat source. It is also an aspect of the present disclosure to provide easy-to-implement and cost-effective methods of using and assembling the thermally-insulative insert device.

Description:
FIELD OF THE DISCLOSURE 
     The present disclosure is generally directed toward a thermally-insulative insert device and specifically directed toward a thermally-insulative insert device comprising internal and external threads. 
     BACKGROUND 
     Many products require management of heat transfer between product components. Solutions vary widely based on the application and design constraints. In electronics, relatively small components traditionally operate in proximity to heat sources, to include resistors, diodes, and power sources. Furthermore, some electronic components are secured to other components, such as a substrate, by metal screws, which serve to transfer thermal energy between components. Metal screws are used because of their low cost, strength and ease of use in assembly operations. Typically, size and manufacturability constraints in electronics applications prevent use of thermal wrappings or blankets common in, for example, large-scale industrial applications. 
     Traditional approaches to provide thermal management or control between product components operating in proximity to heat sources do not effectively or efficiently prevent or mitigate the transfer of thermal energy enabled by metallic attachment screws. Some attempts to control heat transfer between product components use specialized screws or threaded-components which raise cost and decrease manufacturing efficiencies. 
     SUMMARY 
     It is, therefore, one aspect of the present disclosure to provide a thermally-insulative insert device which allows attachment of an assembled part to a heat source or heat-carrying component while reducing heat transfer between the assembled part and the heat source or heat-carrying component. It is also an aspect of the present disclosure to provide easy-to-implement and cost-effective methods of using and assembling a thermally-insulative insert device in a larger system. 
     The thermally-insulative insert device, in some embodiments, is fitted with internal and external threads. The device&#39;s internal threads engage an attachment screw used to secure an assembled part to the heat source or heat-carrying component. The device&#39;s external threads engage the heat source or heat-carrying component. The thermally-insulative insert device is thereby positioned between the attachment screw and the heat source or heat-carrying component, serving to separate and to insulate the transfer of heat from the heat source or heat-carrying component, via the attachment screw, to the assembled part. 
     In one embodiment, a thermally-insulative threaded insert device is disclosed, the device comprising: an outer surface configured to threadably engage a heat source or heat-carrying component; and an inner surface configured to threadably engage a screw. 
     In one embodiment, a thermally-insulative threaded insert system is disclosed, the system comprising: an attachment screw comprising a screw head and a screw threaded portion; a thermally-conductive component; an assembly part; a thermally-insulative threaded insert device comprising: an outer surface configured to threadably engage the thermally-conductive component; and an inner surface configured to threadably engage the screw; an upper surface; a lower surface; wherein the screw head engages the assembly part, the screw threaded portion engages the internal surface and the thermally-conductive component engages the external surface; wherein the thermally-insulative threaded insert device reduces thermal communication between the assembly part and the thermally-conductive component. 
     In one embodiment, a method of assembling a thermally-insulative threaded insert device system is disclosed, the method comprising: providing a heat source; tapping a hole into the heat source or a component thermally-coupled to the heat source; inserting a thermally-insulative threaded insert device into the hole, the insert device comprising: an outer surface configured to threadably engage the hole; an inner surface configured to threadably engage a screw; an upper surface comprising a flange; and a lower surface; positioning an assembled part above and adjacent the flange of the insert device; and inserting a screw into the threaded insert device wherein the screw head engages the assembly part and the screw threaded portion engages the internal surface; wherein the thermally-insulative threaded insert device reduces thermal communication between the assembly part and the heat source. 
     The present disclosure will be further understood from the drawings and the following detailed description. Although this description sets forth specific details, it is understood that certain embodiments of the invention may be practiced without these specific details. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the disclosure and together with the general description of the disclosure given above and the detailed description of the drawings given below, serve to explain the principles of the disclosures. 
       It should be understood that the drawings are not necessarily to scale. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the disclosure is not necessarily limited to the particular embodiments illustrated herein. 
       The present disclosure is described in conjunction with the appended figures: 
         FIG. 1A  is a top-view of a first assembled system in accordance with at least some embodiments of the present disclosure; 
         FIG. 1B  is a cross-sectional side-view along line A-A depicted in  FIG. 1A ; 
         FIG. 2A  is a top-view of a second assembled system in accordance with at least some embodiments of the present disclosure; 
         FIG. 2B  is a cross-sectional side-view along line B-B depicted in  FIG. 2A ; 
         FIG. 3  is detailed cross-sectional side-view of a thermally-insulative threaded insert device in accordance with at least some embodiments of the present disclosure; and 
         FIG. 4  is a flow-diagram representation of a method of employing a thermally-insulative threaded insert device in an assembled system in accordance with at least some embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The ensuing description provides embodiments only, and is not intended to limit the scope, applicability, or configuration of the claims. Rather, the ensuing description will provide those skilled in the art with an enabling description for implementing the described embodiments. Preferred embodiments are described to illustrate the present invention, not to limit its scope, which is defined by the claims. Like elements in various embodiments are commonly referred to with like reference numerals. It being understood that various changes may be made in the function and arrangement of elements without departing from the spirit and scope of the appended claims. 
     Referring now to  FIGS. 1-4 , representations and configurations of a device and system, and methods of use of the device and system, are shown. 
     In regard to  FIGS. 1A-B , corresponding top and cross-sectional side views of a first assembled system  100  are provided.  FIG. 1A  is a top-view of the system  100  and  FIG. 1B  is the corresponding cross-sectional side view along section line A-A. The system  100  and components thereof will be described in accordance with at least some embodiments of the present disclosure. It should be appreciated that assembled parts and functions thereof can be found in many different fields of application—particularly where heat transfer or thermal management are of concern. Specifically, the features and functions disclosed herein can be employed in any assembled system where one component is desired to be thermally or electrically insulated from another component. 
     The illustrative system  100  depicted in  FIGS. 1A-B  includes a heat source  110  or thermally-conductive component that is thermally coupled to a heat source (termed a “heat source” herein for ease of discussion), thermal insulation layer  120 , assembly part  130 , screw  140  and thermally-insulative threaded insert device  160 . The threaded insert device  160 , in some embodiments, is inserted into a hole or void of the heat source  110  by external threads (see  FIG. 3 ) disposed on an outer circumference of the insert device  160 . The screw  140  is threaded into the interior or inner circumference of the insert device  160 . The screw  140 , in some embodiments, may correspond to a traditional screw as used, for example, in the fabrication of electronic assemblies, mechanical assemblies, etc. The screw  140  is commonly made of a conductive material, such as a metallic material like steel, aluminum, a conductive composite, etc. The head of the screw  140  rests on or interfaces with a top of the assembly part  130 . As such, the assembly part  130  is disposed between the screw head and the insert device  160 . 
     The insert device  160 , in some embodiments, comprises a dual-cylindrical shape—that is a bottom portion of the insert device  160  may be shaped similar to a cylinder of a first circumference while a top portion of the insert device  160  may be shaped similar to a cylinder of a second circumference. As can be seen in  FIGS. 1A and 1B , the top portion of the insert device  160  may be flatter than the bottom portion and, therefore, may have more of a disk shape than an extended cylindrical shape as exhibited by the bottom portion. As can be specifically seen in  FIG. 1A , the shape of the top portion of the insert device  160  when viewed from above may be generally circular. It should be appreciated, however, that the insert device  160  may alternatively have a non-circular top portion. For instance, the top portion of the insert device  160  may be polygonal with one or more straight edges (e.g., triangle, rectangle, hexagon, quadrilateral, irregular polygon, etc.) that can accommodate a wrench or the like. 
     A thermal insulation layer  120  may be disposed between the heat source  110  and the top portion of the insert device  160 , as shown. In this, the thermally-insulative threaded insert device  160  reduces thermal communication between the assembly part  130  and the heat source  110  in that the thermal communication between the assembly part  130  and the heat source  110  by way of the (conductive) screw  140  must pass through the thermally insulative threaded insert device  160 . In some configurations, the thermal insulation layer  120  may be absent, and thus the bottom surface of the top portion of the thermally insulative threaded insert device  160  rests directly on top of the heat source  110 . 
     A second configuration of the system  100  is depicted in  FIGS. 2A-B .  FIGS. 2A-B  provide corresponding top and cross-sectional side views of the system  100  in the second configuration.  FIG. 2A  is a top-view of the system  100  and  FIG. 2B  is the corresponding cross-sectional side view along section line B-B. 
     In the configuration depicted of  FIGS. 2A-B , the system  100  is shown to include a heat source  110 , thermal insulation layer  120 , assembly part  130 , screw  140  and thermally-insulative threaded insert device  160 . In this configuration, the threaded insert device  160  is inserted substantially flush with the upper surface of the heat source  110 . In other words, an upper surface of the top portion of the insert device  160  is substantially co-planar with the upper surface of the heat source  110 . This configuration results in a lower profile of the assembled stack of screw  140 , assembly part  130  and thermal insulation layer  120 . 
     The configuration of  FIGS. 2A-B  may be accommodated by first tapping a hole (threaded or un-threaded) into the heat source  110 , and then counter-sinking a portion of the tapped hole to allow the flush-fitting of the insert device  160 . The screw  140  may then be threaded into the interior of the insert device  160 . The screw head of the screw  140  thus rests on top of the assembly part  130 . As such, the assembly part  130  is disposed between the screw head and the insert device  160 . A thermal insulation layer  120  may be disposed between the heat source  110  and a portion of the top portion of the insert device  160  and a portion of the heat source  110  upper surface, as shown. In this configuration of the system  100 , the thermally-insulative threaded insert device  160  reduces thermal communication between the assembly part  130  and the heat source  110  in that the thermal communication between the assembly part  130  and the heat source  110  by way of the (metallic) screw  140  must pass through the thermally insulative threaded insert device  160 . 
       FIG. 3  depicts a detailed cross-sectional side-view of the thermally-insulative threaded insert device  160  in accordance with at least some embodiments of the present disclosure. The insert device  160  comprises an top portion  162 , bottom portion  164 , interior or inner surface  168  with screw threads and exterior or outer surface  167  with screw threads. The top portion  162 , in some embodiments, forms a flange with an upper surface  163 . The insert device  160  also comprises a lower exterior surface  165  and lower interior surface  166 , and, in some embodiments, is generally circular when view from above or below. The top portion  162  may include a flange, as shown. 
     In one embodiment, the external threads  167  are absent and the insert device  160  engages the heat source  110  by an interference fit (e.g., a radius of the bottom portion  164  is greater proximate to the top portion  162  than a radius of the bottom portion  164  that is distal to the top portion  162 ). In another embodiment, the external threads  167  are absent and the insert device  160  engages the heat source  110  with a gap wherein a glue or adhesive is applied to secure the insert device  160  within the hole of the heat source  110 . In yet another embodiment, the insert device  160  does not comprise a flange at the top portion  162 , but rather is of a substantially uniform circular cross-section meaning that the circumference of the top portion  162  is substantially similar or identical to the circumference of the bottom portion  164 . 
     The thermally insulative threaded insert device  160 , in some embodiments, is formed of a thermally-insulating material to include one or more of plastics, nylons, polycarbonate, rubber, wood, and other materials known to those skilled in the art to provide thermal insulation. In one embodiment, the thermally-insulative threaded insert device  160  is constructed of a plastic material or plastic composite. For example, the material may comprise polyethylene terephthalate (PET), polyethylene terephthalate glycol (PET G), crystalline PET (PET-C) i.e. a biaxially stretched polyethylene terephthalate. 
     Thermally insulative threaded insert device  160  may be solid or may be configured to form a chamber and/or void internally. The chamber and/or void may be filled with a different material than that forming the void or chamber. The chamber may be configured to form a vacuum or; the vacuum may be filled with air or other known gases with non-conductive properties. In some embodiments, the insert device  160  may be manufactured using an injection molding process, blow molding process, casting process, etc. In other embodiments, the insert device  160  may comprise a metal that is plated or coated with a non-conductive material, thereby making the entirety of the exposed surface of the insert device  160  non-conductive. 
     In one embodiment, the assembly part  130  is an element that generates heat and the heat source  110  is not an element that generates heat. For example, the assembly part  130  may comprise a light source which generates heat, and the heat source  110  may comprise a non-conductive mounting plate. In such an embodiment, the thermally insulative threaded insert device  160  still functions, among other things, to secure the assembly part  130  and the heat source  110  without serving as a conduit for thermal heat transfer. 
     The term “screw” may include other attachment means, such as pins without external threads, pins with leaf-spring type attachments and interference-fit type pins. The screw may be formed of any metallic materials or constructions known to those skilled in the art. 
     The heat source may be any heat-transfer element known to those skilled in the art, to include heat sources contained in an integrated circuit or mounting board of an apparatus, or any surface mount device (SMD) or pin through hole (PTH) configuration capable of generating heat. The heat source  110  may be a heat sink, a metal connected to an LED, and heat sources associated with LED lighting applications. The heat source  110  may be made of a material consisting of copper, aluminum, titanium, tungsten, silicon carbide, a conductive epoxy, a conductive polymer, a metal and any material known to one skilled in the art to act as a conductive element. In one embodiment, the conductive element  110  is a plate. 
     An embodiment of a method of creating an assembled system by using one or more insert device  160  will now be described with reference to  FIG. 4 . 
     A general order for the steps of the method  400  of a method of assembling a thermally insulative threaded insert device system is shown in  FIG. 4 . The method  400  starts with a start operation  405  and ends with an end operation  495 . The method  400  can include more or fewer steps or can arrange the order of the steps differently than those shown in  FIG. 4 . 
     Hereinafter, the method  400  shall be explained with reference to the systems, components, elements, etc. described in conjunction with  FIGS. 1-3 . The method  400 , in some embodiments results in an assembled system  100  as shown in either  FIGS. 1A-B  or  FIGS. 2A-B . 
     After beginning the method with start operation  405 , a heat source  110  is received, as depicted in step  410 . The heat source  110  may host a plurality of assembly parts  130 , although such a configuration is not required. 
     In step  415 , one or more holes are drilled or tapped into the heat source  110 . Any of several methods know to those skilled in the art for drilling and tapping holes may be used. A counter-sink is also optionally formed at the upper end of the tapped hole to enable the flange-equipped thermally insulative threaded insert device  160  (as shown in  FIG. 3 ) into the heat source  110  so as to present a substantially planar surface at the intersection of the insert device edge and heat source  110 . The hole may alternatively be first drilled, then a countersink formed, and then tapped. Any means known to those skilled in the art for providing a countersink may be used. 
     In step  420 , the thermally insulative threaded insert device  160  is inserted into the hole of the heat source  110 . The insert device  160  may be inserted such that the flange of the insert device  160  fits within the counter-sink of the tapped hole of the heat source  110 . 
     In step  425 , the thermal insulation layer  120  is stacked above the flush-mounted flange of the insert device  160  and heat source  110 , and the assembled part  130  is positioned above the thermal insulation layer  120 . 
     In step  430 , the screw  140  is threaded into the interior of the insert device  160  such that the screw head  140  engages the assembly part  130 , wherein the thermally-insulative threaded insert device reduces thermal communication between the assembly part and the heat source. 
     The process ends at step  495  in producing one or more thermally insulative threaded insert device systems  100 . 
     While the pictorial representations and flowcharts have been discussed and illustrated in relation to a particular sequence of events, it should be appreciated that changes, additions, and omissions to this sequence can occur without materially affecting the operation of the disclosed embodiments, configuration, and aspects. 
     The present disclosure, in various aspects, embodiments, and/or configurations, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various aspects, embodiments, configurations embodiments, sub-combinations, and/or subsets thereof. Those of skill in the art will understand how to make and use the disclosed aspects, embodiments, and/or configurations after understanding the present disclosure. The present disclosure, in various aspects, embodiments, and/or configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and/or configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation. 
     The foregoing discussion has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more aspects, embodiments, and/or configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and/or configurations of the disclosure may be combined in alternate aspects, embodiments, and/or configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claims require more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspect, embodiment, and/or configuration. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure. 
     Moreover, though the description has included description of one or more aspects, embodiments, and/or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and/or configurations to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter.