Patent Description:
Electrical circuits, such as power amplifier circuits, generate heat during normal operation. Heat build-up may undesirably increase the temperature of the various components of the electrical circuit. If this heat is not sufficiently managed, for example by dissipation to a heat sink, the electrical device may overheat, resulting in damage to the electrical component. Connecting an electrical component directly to the heat sink, however, may undesirably create an electrical connection between the electrical component and the heat sink, i.e., a flow of electrical current, and disrupt the operation of the electrical component and circuit. "<NPL>] discloses a thick film component for thermal management of electronic devices. Furthermore <CIT> discloses a heat dissipation structure of an integrated circuit device.

As such, a need currently exists for a thermal connector having a low thermal resistance and a high electrical resistance.

The present invention is given by claim <NUM>. In accordance with one embodiment of the present invention, a thermal connector is disclosed. The thermal connector includes an electrically insulating beam having a first end face at a first end and a second end face at a second end. The second end face may be opposite the first end face in an X direction. The beam may have a width in a Y direction which is perpendicular to the X direction. The beam may also have a top face and a bottom face offset from the top face in a Z direction, which is perpendicular to each of the X and Y directions. The thermal connector may include a first terminal attached to the bottom face and adjacent the first end and a second terminal attached to the top face and adjacent the first end. The connector may have an overall thickness in the Z direction, which includes the first and second terminals. The overall thickness may be greater than <NUM> inch (<NUM>) and less than <NUM> inch (<NUM>).

Repeat use of reference characters in the present specification and drawing is intended to represent same or analogous features or elements of the invention.

Generally speaking, the present invention is directed to a thermal connector which may be connected between an electrical component and a heat sink, or other thermal point, to improve heat dissipation from the electrical component to the heat sink. The thermal connector may have one or more terminals at each end to aid with connection to the heat sink and electrical component. The terminals may be electrically separate and the beam may have a high electrical resistance such that a flow of electrical current between the terminals may be prevented or substantially prevented. This configuration may be advantageous because it may dissipate heat from the electrical component to the heat sink without electrically connecting the component to the heat sink, which might disrupt the operation of the component.

Referring to <FIG>, the thermal connector <NUM> comprises an electrically insulating beam <NUM> having a first end face <NUM> at a first end <NUM> and a second end face <NUM> at a second end <NUM>. The second end face <NUM> may be opposite the first end face <NUM> in an X direction <NUM>. In some embodiments, the first end face <NUM> may be parallel with the second end face <NUM>. The beam <NUM> may have a width in a Y direction <NUM> which is perpendicular to the X direction <NUM>. In some embodiments, the width of the beam <NUM> may be equal to an overall width <NUM> of the thermal connector <NUM>. The beam <NUM> may also have a top face <NUM> and a bottom face <NUM>. The bottom face <NUM> may be offset from the top face <NUM> in a Z direction <NUM>, which is perpendicular to each of the X and Y directions <NUM>, <NUM>. In some embodiments, the top and bottom faces <NUM>, <NUM> of the beam <NUM> may be parallel. The thermal connector <NUM> may include a first terminal <NUM> attached to the bottom face <NUM> of the beam <NUM> and adjacent the first end <NUM>. The thermal connector <NUM> may include a second terminal <NUM> attached to the top face <NUM> and adjacent the first end <NUM> of the beam <NUM>.

Still referring to <FIG>, in some embodiments, the thermal connector <NUM> may have four terminals. For example, in addition to the first and second terminals <NUM>, <NUM>, discussed above, the thermal connector <NUM> may include a third terminal <NUM> attached to the bottom face <NUM> of the beam <NUM> and adjacent the second end <NUM>. The thermal connector <NUM> may also include a fourth terminal <NUM> attached to the top face <NUM> and adjacent the second end <NUM>.

Each terminal may extend to a respective edge adjacent a respective end face. For example, the first terminal <NUM> may extend on the bottom face <NUM> of the beam <NUM> along an edge between the bottom face <NUM> of the beam <NUM> and the first end face <NUM> of the beam <NUM>. The second terminal <NUM> may extend on the top face <NUM> of the beam <NUM> along an edge between the top face <NUM> and first end face <NUM> of the beam <NUM>. Similarly, the third terminal <NUM> may extend on the bottom face <NUM> of the beam <NUM> along an edge between the second end face <NUM> and the bottom face <NUM> of the beam <NUM>. Lastly, the fourth terminal <NUM> may extend on the top face <NUM> of the beam <NUM> along an edge between the top face <NUM> and the second end face <NUM> of the beam <NUM>.

The first terminal <NUM> may have a bottom surface <NUM> parallel with the bottom face <NUM> of the beam <NUM>, and the second terminal <NUM> may have a top surface <NUM> parallel with the top face <NUM> of the beam <NUM>. An overall thickness <NUM> of the connector may be defined as a distance between the bottom surface <NUM> of the first terminal <NUM> and the top surface <NUM> of the second terminal <NUM> in the Z direction <NUM>, for example. In some embodiments, however, the thermal connector <NUM> may not include the second and/or fourth terminals <NUM>, <NUM> on the top face <NUM> of the beam <NUM>. In such an embodiment, the overall thickness <NUM> may be defined as the distance between the bottom surface <NUM> of the first terminal <NUM> and the top face <NUM> of the beam <NUM> in the Z direction <NUM>.

Each of the terminals may have a respective terminal length <NUM> in the X direction <NUM> and a respective terminal thickness <NUM> in the Z direction <NUM> (labeled in <FIG> for the third terminal <NUM> only for clarity). The overall thickness <NUM> of the thermal connector <NUM> in the Z direction <NUM> may include the respective thicknesses of the terminals in the Z direction <NUM>.

In some embodiments, the thermal connector <NUM> may have an overall length <NUM> in the Y direction <NUM>. The overall length <NUM> and overall width <NUM> of the thermal connector <NUM> may be equal to the length and width, respectively, of the beam <NUM>, as illustrated in <FIG>. For example, the terminals may not extend beyond the edges of the top and bottom faces <NUM>, <NUM>. In other embodiments, however, one or more of the terminals may extend beyond the respective edges of the top and/or bottom face <NUM>, <NUM> of the beam <NUM>. In that case, the overall length <NUM> and/or overall width <NUM> of the thermal connector <NUM> may be larger than the respective length and and/or width of the beam <NUM>. This may advantageously provide a larger terminal to connect an electrical component and/or heat sink to the thermal connector <NUM>.

Referring to <FIG>, in some embodiments, the thermal connector <NUM> may include a first wrap-around terminal <NUM> which wraps, or extends, around the first end <NUM> of the beam <NUM> such that the first wrap-around terminal <NUM> is attached to both the top face <NUM> of the beam <NUM> and the bottom face <NUM> of the beam <NUM>. The first wrap-around terminal <NUM> may include a first terminal <NUM> and a second terminal <NUM>, similar to the previous embodiment, and may also include a first end face terminal <NUM>. The first end face terminal <NUM> may connect the first terminal <NUM> with the second terminal <NUM> and may be attached to the first end face <NUM> (shown in <FIG>) of the beam <NUM>. In one embodiment, the first wrap-around terminal <NUM> may be a single continuous terminal. For example, the first terminal <NUM>, second terminal <NUM>, and the first end face terminal <NUM> may be portions of the first wrap-around terminal <NUM>. Additionally, the first wrap-around terminal <NUM> may be formed using any suitable technique, and may be formed in a single step, for example.

A second wrap-around terminal <NUM> may be similarly configured such that the second wrap-around terminal <NUM> wraps around the second end <NUM> of the beam <NUM> and is attached to both the top face <NUM> of the beam <NUM> and the bottom face <NUM> of the beam <NUM>. For example, the second wrap-around terminal <NUM> may include a third terminal <NUM> and a fourth terminal <NUM>, similar to the previous embodiment, and may additionally include a second end face terminal <NUM>. The second end face terminal <NUM> may be attached to the second end face <NUM> (shown in <FIG>) of the beam <NUM> and may connect the third terminal <NUM> with the fourth terminal <NUM>. In one embodiment, the second wrap-around terminal <NUM> may be a single continuous terminal. For example, the third terminal <NUM>, fourth terminal <NUM>, and the second end face terminal <NUM> may be portions of the second wrap-around terminal <NUM>. Additionally, the second wrap-around terminal <NUM> may be formed using any suitable technique, and may be formed in a single step, for example.

In some embodiments, the first wrap-around terminal <NUM> may span the width of the beam <NUM> across the first end face <NUM> of the beam <NUM> such that the width of the beam <NUM> is equivalent to the overall width <NUM> of the connector <NUM>. The second wrap-around terminal <NUM> may similarly span the width of the beam <NUM> across the second end face <NUM> of the beam <NUM>. For example, the first wrap-around terminal <NUM> may have a top surface <NUM> which is adjacent and/or parallel with the top face <NUM> of the beam <NUM>. The first wrap-around terminal <NUM> may also have a bottom surface <NUM> which is adjacent and/or parallel with the bottom face <NUM> of the beam <NUM>. The overall thickness <NUM> of the connector <NUM> may be defined as the distance in the Z direction <NUM> between the top surface <NUM> of the first wrap-around terminal <NUM> and the bottom surface <NUM> of the first wrap-around terminal.

Each of the terminals may have a respective terminal length <NUM> in the X direction <NUM> and terminal thickness <NUM> in the Z direction <NUM> (labeled only on the second wrap-around terminal <NUM> for clarity). In some embodiments, the portion of the first wrap-around terminal <NUM> attached to the top surface <NUM> may have a different length than the portion of the first wrap-around terminal <NUM> attached to the bottom face <NUM>. In other embodiments, these lengths may be the same or similar as illustrated in <FIG>.

The first and second wrap-around terminals <NUM>, <NUM> may also have respective terminal thicknesses <NUM> in the X direction <NUM> along the first and second end faces <NUM>, <NUM> of the beam <NUM> direction (labeled on the second terminal <NUM> only for clarity). In some embodiments, the terminal thickness <NUM> in the X direction <NUM> of the second wrap-around terminal <NUM> may be approximately equal to the terminal thickness <NUM> in the Z direction <NUM> of the second wrap-around terminal <NUM> such that the second wrap-around terminal <NUM> has a uniform thickness. In some embodiments, the first wrap-around terminal <NUM> may be similarly configured. In other embodiments, the terminal thickness <NUM> in the Z direction <NUM> may be different than the terminal thickness <NUM> in the X direction <NUM>, for example.

Referring to <FIG>, the overall length <NUM> of the thermal connector <NUM> may include each respective terminal thickness <NUM> in the X direction <NUM> of the first and second wrap-around terminals <NUM>, <NUM>. The thermal connector <NUM> may also have an overall width <NUM> in the X direction <NUM>. In some embodiments, the overall width <NUM> of the thermal connector <NUM> may be equal to the width of the beam <NUM> because the respective widths of first and second wrap-around terminals <NUM>, <NUM> may be equal to or less than the width of the beam <NUM>. In other embodiments, however, the first and second wrap-around terminals <NUM>, <NUM> may have respective widths greater than the width of the beam <NUM> such that at least one of first or second wrap-around terminals <NUM>, <NUM> extend beyond an edge of the beam <NUM> in the Y direction <NUM>. This may provide a larger terminal to connect the electrical component <NUM> and/or heat sink <NUM> to the thermal connector <NUM>.

As noted above, the overall thickness <NUM> of the thermal connector <NUM> in the Z direction <NUM> may include the thicknesses <NUM> of the first and second terminals <NUM>, <NUM> in the Z direction <NUM>. In some embodiments, the overall thickness <NUM> of the thermal connector <NUM> may be greater than <NUM> inch (<NUM>) and less than <NUM> inch (<NUM>). For example, in some embodiments, the overall thickness <NUM> may be between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), in other embodiments between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), in other embodiments between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), in other embodiments between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>). In some embodiments, the overall thickness <NUM> may be about <NUM> inch (<NUM>) or greater. For instance, the thickness may be between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), in other embodiments, between about <NUM> (<NUM>) inch and about <NUM> inch (<NUM>), in other embodiments, between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), in other embodiments, between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and, in other embodiments, between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>).

In some embodiments, the overall length <NUM> of the thermal connector <NUM> may be between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments, between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments, between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments, between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments, between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments, between about <NUM> inch (<NUM>) and <NUM> inch (<NUM>).

In some embodiments, the overall width <NUM> of the thermal connector <NUM> may be between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments between about <NUM> inch (<NUM>) about <NUM> inch (<NUM>), and in some embodiments between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>), and in some embodiments between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>).

In some embodiments, the overall length <NUM> of the thermal connector <NUM> may be between about <NUM> and about <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>, in some embodiments, between about <NUM> and about <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>, and, in some embodiments, between about <NUM> and about <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>.

In other embodiments, the overall length <NUM> of the thermal connector <NUM> may be between about <NUM> and about <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>, and in some embodiments between about <NUM> and about <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>, and in some embodiments between about <NUM> and about <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>. In other embodiments, the overall length <NUM> of the thermal connector <NUM> may be between <NUM> and <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>, and in some embodiments between about <NUM> and <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>, and in some embodiments between about <NUM> and <NUM> times greater than the overall thickness <NUM> of the thermal connector <NUM>.

In some embodiments, each of the overall length <NUM> and the overall width <NUM> of the thermal connector <NUM> may be between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>). For example, in some embodiments, each of the overall length <NUM> and the overall width <NUM> of the thermal connector <NUM> may be between about <NUM> inch (<NUM>) and about <NUM> inch (<NUM>).

In some embodiments, the thermal resistance across the overall length <NUM> of the thermal connector <NUM> may be between about <NUM>/W and about <NUM>/W at about <NUM>, and in some embodiments between <NUM>/W and about <NUM>/W at about <NUM>. For the embodiment depicted in <FIG>, the thermal resistance may be associated with a heat flow between the first and third terminals <NUM>, <NUM>, for example. For the embodiment depicted in <FIG>, the thermal resistance may be associated with a heat flow between the first and second terminals <NUM>, <NUM>, for example.

In some embodiments, the thermal connector <NUM> may have an aspect ratio between the overall length <NUM> and the overall width <NUM> calculated as the length divided by the width. A "thermal aspect resistance" parameter may be defined as the ratio of the aspect ratio to the thermal resistance of the thermal connector <NUM> across the length of the thermal connector <NUM> (e.g., between the first and third terminals <NUM>, <NUM> for the embodiment of the thermal connector <NUM> depicted in <FIG>). The "thermal aspect resistance" parameter may be defined as the thermal resistance divided by the aspect ratio. The "thermal aspect resistance" parameter value may be indicative of the effectiveness of the thermal connector <NUM> based on its size. For example, a low "thermal aspect resistance" may indicate that the thermal connector <NUM> not only has a low thermal resistance across the length of the thermal connector <NUM> but also that the thermal connector <NUM> has a reasonably high aspect ratio, such that it may span a reasonable length compared to its width. In some embodiments, the "thermal aspect resistance" parameter may be between about <NUM> C/W and about <NUM> C/W at about <NUM>. In some embodiments, the "thermal aspect resistance" parameter may be between about <NUM> C/W and about <NUM> C/W at about <NUM>. In some embodiments the "thermal aspect resistance" parameter may be between about <NUM>/W and about <NUM>/W at about <NUM>. In some embodiments the "thermal aspect resistance" parameter may be between about <NUM> C/W and about <NUM>/W at about <NUM>. In some embodiments the "thermal aspect resistance" parameter may be between about <NUM>/W and about <NUM>/W at about <NUM>.

As is known in the art, thermal resistivity and thermal conductivity of a material are inversely related. Thus, a low thermal resistivity correlates with a high thermal conductivity. In some embodiments, the electrically insulating beam <NUM> may be made from any suitable material having a generally low thermal resistivity (e.g., less than about <NUM> x <NUM>-<NUM> m•°C/W), and a generally high electrical resistivity (e.g., greater than about <NUM><NUM> Ω•cm). A thermal resistivity of <NUM> x <NUM>-<NUM> m•°C/W is equivalent with a thermal conductivity of about <NUM> W/m•°C. In other words, suitable materials for the beam <NUM> may have a generally high thermal conductivity, such as greater than about <NUM> W/m•°C.

For example, in some embodiments, the electrically insulating beam <NUM> may be made from a material having a thermal conductivity between about <NUM> W/m•°C and about <NUM> W/m•°C at about <NUM>. In other embodiments, the electrically insulating beam <NUM> may be made from a material having a thermal conductivity between about <NUM> W/m•°C and about <NUM> W/m•°C at about <NUM>. In other embodiments, the electrically insulating beam <NUM> may be made from a material having a thermal conductivity between about <NUM> W/m•°C and about <NUM> W/m•°C at about <NUM>.

In some embodiments, the beam <NUM> may comprise aluminum nitride, beryllium oxide, aluminum oxide, boron nitride, silicon nitride, magnesium oxide, zinc oxide, silicon carbide, any suitable ceramic material, and mixtures thereof.

In some embodiments, the electrically insulating beam <NUM> may comprise aluminum nitride. For example, in some embodiments the electrically insulating beam <NUM> may be made from any suitable composition including aluminum nitride. In some embodiments, the beam <NUM> may be made primarily from aluminum nitride. For example, the beam <NUM> may contain additives or impurities. In other embodiments, the electrically insulating beam <NUM> comprises beryllium oxide. For example, in some embodiments the electrically insulating beam <NUM> may be made from any suitable composition including beryllium oxide. In some embodiments, the beam <NUM> may be made primarily from beryllium oxide. For example, the beam <NUM> may contain additives or impurities.

In some embodiments, the terminals may include an outer layer over a substrate. The substrate may be magnetic in some embodiments, and non-magnetic in other embodiments. The outer layer may be formed from any suitable material, including, for example, corrosion-resistant materials. For example, in some embodiments, the terminals may comprise an outer layer of gold, silver, platinum, nickel, and/or a mixture or compound thereof. For example, in one embodiment, at least one of the first terminal <NUM> or the second terminal <NUM> may comprise gold. In some embodiments, at least one of the first terminal <NUM> or the second terminal <NUM> may comprise a magnetic material. In some embodiments, the magnetic material may be a substrate and the outer layer may be disposed over the magnetic material. For example, in one embodiment, one or more of the terminals may include an outer layer of gold disposed over a magnetic substrate, such as a magnetic or magnetized metal. In some embodiments, the substrate may comprise a metal such as copper or steel. In another embodiment, one of more of the terminals may include an outer layer, such as gold, disposed over a non-magnetic substrate, such as a ceramic, for example. In other embodiments, the outer layer may be gold, silver, platinum, nickel, copper, steel, and/or any other suitable material. Similarly, in other embodiments, the substrate may be gold, silver, platinum, nickel, copper, steel, and/or any other suitable material. Moreover, in some embodiments, the terminals may not include an outer layer.

In some embodiments, the thermal connector <NUM> may have a relatively low capacitance value. This may advantageously prevent substantial interference with electric fields, such as radio waves. For example, the thermal connector <NUM> may result in substantially no interference with the performance of electrical components to which the thermal connector <NUM> is connected, such as radio frequency amplifiers. For example, in some embodiments, the capacitance of the thermal connector <NUM> may be <NUM> pF or less. In some embodiments, the capacitance of the thermal connector <NUM> may be <NUM> pF or less. In some embodiments, the capacitance of the thermal connector <NUM> may be <NUM> pF or less. In some embodiments, the capacitance of the thermal connector <NUM> may be <NUM> pF or less. In some embodiments, the capacitance of the thermal connector <NUM> may be <NUM> pF or less. In some embodiments the capacitance of the thermal connector <NUM> may be <NUM> pF or greater. In some embodiments the capacitance of the thermal connector <NUM> may be <NUM> pF or greater.

The thermal connectors <NUM> may be manufactured or fabricated using any suitable technique. For example, the beam <NUM> may be cut from a substrate or wafer, and the terminals may then be formed on each beam <NUM>. Alternatively, the terminals may be formed on a plate-shaped material and then the plate-shaped material may cut into the thermals connectors <NUM>. The terminals may be formed using any suitable process, including, for example, chemical or vapor deposition on the beam <NUM>. Alternatively, in some embodiments, the terminals may be formed by dipping the ends of the beam <NUM> in a liquid form of the terminal material and then allowing the terminal material to harden. The terminals may then be additionally shaped or finished using any suitable method, including for example, grinding or sanding. In some embodiments, the above process may be repeated to produce terminals having multiple layers, e.g., a gold plating over a magnetic or non-magnetic layer.

Referring to <FIG>, in one embodiment, the thermal connector <NUM> may be directly connected between an electrical component <NUM> and a heat sink <NUM>, or any other suitable component. For example, the third terminal <NUM> of the thermal connector <NUM> may be connected with an attachment tab <NUM> of the electrical component, and the first terminal <NUM> may be connected with the heat sink <NUM>. Heat may flow from the attachment tab <NUM> of the electrical component <NUM>, through the third terminal <NUM>, through the beam <NUM>, and out through the first terminal <NUM> to the heat sink <NUM> (as illustrated by the arrow <NUM>).

In other embodiments, multiple thermal conductors may be connected in parallel or series to a single electrical component. For example, multiple thermal conductors may be connected in series, in an end-to-end configuration, to span a distance greater than the length of a single thermal conductor. Multiple thermal conductors may also be connected in parallel between a single electrical component and the heat sink, for example. In other embodiments, multiple heat sinks may be connected using multiple thermal connectors <NUM> to the electrical component.

Lastly, in some embodiments, the thermal connector <NUM> may connect a first electrical component with a second electrical component which may act as a heat sink. For example the second electrical component, while not itself a heat sink, may be connected with a heat sink such that heat may flow from the first electrical component, through the second electrical component, and into the heat sink. One of ordinary skill in the art would understand that still other configurations are possible based on the above disclosure.

In some embodiments, the thermal connector <NUM> may be coupled directly to the electrical component, which may be particularly advantageous for electrical components lacking a suitable attachment tab <NUM>. For example, the thermal connector <NUM> may directly thermally connect an electrical component <NUM> with the heat sink <NUM> as illustrated in <FIG>. The thermal connector <NUM> illustrated in <FIG> has wrap-around terminals as illustrated in <FIG>. The portion of the second wrap-around terminal <NUM> of the thermal connector <NUM> that extends over the second end <NUM> of the beam <NUM> may be directly attached to an exterior face <NUM> of the electrical component. Similarly, a portion of the first wrap-around terminal <NUM> that extends over the first end <NUM> of the beam <NUM> may be attached to a face of the heat sink <NUM>. This configuration may advantageously provide a greater contact surface with at least one of the electrical component <NUM> or the heat sink <NUM>.

Referring to <FIG>, in one embodiment, the electrical component <NUM> may be stacked on top of one or more thermal connectors <NUM> such that the second and fourth terminals <NUM>, <NUM> are attached to the electrical component <NUM> and the first and third terminals <NUM>, <NUM> are attached to the heat sink <NUM>. Heat may flow (as illustrated by arrow <NUM>) from the second and fourth terminals through the beam <NUM> and out through the first and third terminals <NUM>, <NUM> to the heat sink <NUM>.

The connections between the terminals and the electrical component <NUM> and/or heat sink <NUM> may be formed using any suitable method, such as soldering, for example. For example, the thermal connector <NUM> may be connected using an interconnect that attaches to or connects the respective terminals of the thermal connector <NUM>. The interconnect may be made of a conductive material, such as a conductive metal. In one embodiment, the interconnect may be relatively flat or may be one having an increased surface area. Regarding the latter, the interconnect may have projections/protrusions or may also be formed from wires, braids, coils, etc. In this regard, the specific dimensions and configuration of the interconnects is not necessarily limited. Regardless of its form, any of a variety of different conductive materials may be employed, such as copper, tin, nickel, aluminum, etc., as well as alloys and/or coated metals. If desired, the conductive material may optionally be insulated with a sheath material.

In accordance with the present invention, the thermal connectors <NUM> include features that provide electrical tuning with the circuit and/or component to which the thermal connector <NUM> is connected. Such features can alter the radio frequency and/or microwave frequency response and/or characteristics of the thermal connector, for example to provide impedance matching.

Referring to <FIG>, one or more conductive trace(s) <NUM> are formed on the top surface <NUM> of the thermal connector <NUM>. The conductive trace(s) <NUM> may be formed from any suitable material and may have one or more layers, for example as described above with reference to the terminal materials and layer. For example, the conductive trace(s) <NUM> may include gold, silver, platinum, nickel, copper, steel, and/or any other suitable material.

The trace(s) <NUM> may be electrically connected (or integrally formed) with the second terminal <NUM>. The trace(s) <NUM> may generally have an "L" shape that extends towards the fourth terminal <NUM>. The size and dimensions of the trace(s) <NUM> may be selected to provide the desired electrical tuning effects.

Referring to <FIG>, another embodiment of the thermal connector <NUM> is illustrated that includes a conductive trace <NUM> that is configured to provide electrical tuning (e.g., impedance matching). The conductive trace <NUM> is formed on a side surface <NUM> of the thermal connector <NUM>. A second side surface <NUM> may be parallel and opposite the side surface <NUM>. The size and dimensions of the trace(s) <NUM> may be selected to provide the desired electrical tuning effects.

It should be understood that conductive trace(s) are formed on any of the surfaces (e.g., bottom surface <NUM>, top surface <NUM>, first end face <NUM>, second end face <NUM>, and/or one or both of the side surfaces <NUM>, <NUM>) of the thermal connector <NUM>. Furthermore, the trace(s) may be electrically connected with any of the terminals (e.g., first terminal <NUM>, second terminal <NUM>, third terminal <NUM>, and/or fourth terminal <NUM>) of the thermal connector <NUM>. However, the conductive traces generally are not connected in a way that would facilitate electrical flow between the heat source and heat sink. In addition, the conductive traces may be physically located between two or more of the terminals <NUM>, <NUM>, <NUM>, <NUM>.

The number, size, and shape of such traces can be selected to provide one or more desired electrical tuning characteristics (e.g., impedance, resonance frequency, insertion loss, return loss, etc.). As such, the traces may have a variety of suitable shapes and geometries that can be selected to electrically tune the thermal connector <NUM>. As examples, the trace(s) may have an "L" or "T" shape. Similarly, the number of traces can vary, for example between <NUM> and <NUM>, or more.

Referring to <FIG>, in some embodiments, one or more holes <NUM> may be formed in the beam <NUM> and/or terminals (e.g., first terminal <NUM>, second terminal <NUM>, third terminal <NUM>, and/or fourth terminal <NUM>) of the thermal connector <NUM> to electrically tune the thermal connector <NUM>. Such holes <NUM> may be formed using a variety of suitable techniques, including laser drilling. A size and/or number of such holes <NUM> may be selected to electrically tune the thermal connector <NUM>, for example, to provide impedance matching. Referring to <FIG>, a pair of holes <NUM> may extend from the top face <NUM> to the bottom face <NUM> of the thermal connector <NUM>. In other embodiments, holes may extend between side surfaces <NUM>, <NUM> or between end faces <NUM>, <NUM>. Additionally, any suitable number of holes may be provided, including, for example from <NUM> to <NUM>, or more.

The various embodiments of thermal connectors <NUM> disclosed herein may be connected between any suitable heat source and sink. For example, the thermal connector <NUM> may be connected to a heat source, such as a terminal pad or conductive trace, and connected to a grounded cover or thermal via. The thermal via may be formed in a layer of a printed circuit board and may connect with a heat sink. For instance, the thermal connector <NUM> may be connected with the thermal via on a first surface of the layer, and the thermal via may extend through the layer to connect with a heat sink that is located on a second surface that is opposite the first surface.

The thermal connector <NUM> may also be connected between terminals of a transistor (e.g., MOSFET). For example, the thermal connector <NUM> may be connected between gate and ground terminals. As another example, the thermal connector <NUM> may be connected between source and ground terminals.

The various embodiments of thermal connectors <NUM> disclosed herein may find application with any suitable electrical component, such as a power amplifier, filter, synthesizer, computer component, power supply, and/or diode, for example. Specific examples of power amplifier types include Gallium Nitride (GaN) power amplifiers, high radio frequency amplifiers, and the like. Examples of diodes which may be suitable for connection with a thermal component, as described herein, may include diodes specifically adapted for use in lasers, among other types of diodes. For example, referring to <FIG>, in some embodiments, the thermal connector <NUM> may be used to form or improve a thermal connection between a laser diode <NUM> and a heat sink <NUM>. In some embodiments, the thermal connector <NUM> may be used to form or improve a thermal connection between a monitor photodiode <NUM> and the heat sink <NUM>.

The following table shows dimensions and thermal properties for various exemplary embodiments in accordance with aspects of the present invention. <NUM> inch (in) = <NUM>.

Claim 1:
A thermal connector (<NUM>) comprising:
an electrically insulating beam (<NUM>) having a first end face (<NUM>) at a first end (<NUM>) and a second end face (<NUM>) at a second end (<NUM>), the second end face (<NUM>) opposite the first end face (<NUM>) in an X direction (<NUM>), the beam (<NUM>) having a width in a Y direction (<NUM>) perpendicular to the X direction (<NUM>), the beam (<NUM>) having a top face (<NUM>) and a bottom face (<NUM>) which is offset from the top face (<NUM>) in a Z direction (<NUM>), the Z direction (<NUM>) being perpendicular to each of the X and Y directions (<NUM>, <NUM>);
a first terminal (<NUM>) attached to the bottom face (<NUM>) and adjacent the first end (<NUM>);
a second terminal (<NUM>) attached to the top face (<NUM>) and adjacent the first end (<NUM>); characterised by
a conductive trace (<NUM>) formed on one of the first end face (<NUM>), the second end face (<NUM>), the top face (<NUM>), or the bottom face (<NUM>) of the electrically insulating beam (<NUM>), the conductive trace being configured to provide electrical tuning.