PATENT DOCUMENT

Publication Number: US-8976528-B2
Application Number: US-201213614996-A
Country: US
Kind Code: B2

Title: Fasteners and dual-thickness thermal stages in electronic devices

Abstract:
The disclosed embodiments provide a system that facilitates heat transfer in an electronic device. The system includes a heat pipe configured to conduct heat away from a heat-generating component in the electronic device. The system also includes a thermal stage disposed along a thermal interface between the heat-generating component and the heat pipe, wherein the thermal stage applies a spring force between the heat-generating component and the heat pipe. The thermal stage includes a first thickness to accommodate the heat pipe and a second thickness that is greater than the first thickness to increase a spring force between the heat-generating component and the heat pipe. Finally, the system includes a set of fasteners configured to fasten the thermal stage to a surface within the electronic device and form a thermal gap between the heat pipe and an enclosure of the electronic device.

Claims:
What is claimed is: 
     
       1. A system for facilitating heat transfer in an electronic device, comprising:
 a heat pipe configured to conduct heat away from a heat-generating component in the electronic device; and 
 a thermal stage disposed along a thermal interface between the heat-generating component and the heat pipe, wherein the thermal stage applies a spring force between the heat-generating component and the heat pipe; and 
 a set of fasteners configured to:
 fasten the thermal stage to a surface within the electronic device; and 
 form a thermal gap between the heat pipe and an enclosure of the electronic device; 
 
 wherein the set of fasteners comprises a screw; 
 wherein the thermal gap is formed by a head of the screw; and 
 wherein the head comprises an insulating material. 
 
     
     
       2. The system of  claim 1 , wherein the surface is a printed circuit board (PCB) in the electronic device. 
     
     
       3. The system of  claim 1 , wherein the heat-generating component is a central processing unit (CPU). 
     
     
       4. A method for facilitating heat transfer in an electronic device, comprising:
 disposing a thermal stage along a thermal interface between a heat-generating component in the electronic device and a heat pipe; and 
 fastening the thermal stage to a surface within the electronic device using a set of fasteners; and 
 using the set of fasteners to form a thermal gap between the heat pipe and an enclosure of the electronic device; 
 wherein the set of fasteners comprises a screw; 
 wherein the thermal gap is formed by a head of the screw; and 
 wherein the head comprises an insulating material. 
 
     
     
       5. The method of  claim 4 , wherein the surface is a printed circuit board (PCB) in the electronic device. 
     
     
       6. The method of  claim 4 , wherein the heat-generating component is a central processing unit (CPU). 
     
     
       7. An electronic device, comprising:
 a heat-generating component, wherein the heat-generating component is a processor or a memory; 
 a heat pipe configured to conduct heat away from the heat-generating component; 
 a thermal stage disposed along a thermal interface between the heat-generating component and the heat pipe; and 
 a set of fasteners configured to:
 fasten the thermal stage to a surface within the electronic device; and 
 form a thermal gap between the heat pipe and an enclosure of the electronic device; 
 
 wherein the set of fasteners comprises a screw; 
 wherein the thermal gap is formed by a head of the screw; and 
 wherein the head comprises an insulating material. 
 
     
     
       8. The electronic device of  claim 7 , wherein the surface is a printed circuit board (PCB) in the electronic device. 
     
     
       9. A system for facilitating heat transfer in an electronic device, comprising:
 a heat pipe configured to conduct heat away from a heat-generating component in the electronic device; and 
 a thermal stage disposed along a thermal interface between the heat-generating component and the heat pipe, comprising: 
 a first thickness to accommodate the heat pipe, and 
 a second thickness that is greater than the first thickness to increase a spring force between the heat-generating component and the heat pipe. 
 
     
     
       10. The system of  claim 9 , wherein the thermal interface further comprises:
 a thermal interface material (TIM) disposed between the heat-generating component and the thermal stage. 
 
     
     
       11. The system of  claim 9 , wherein the heat pipe is joined to the thermal stage using a solder. 
     
     
       12. The system of  claim 9 , wherein the first thickness decreases an overall thickness of the electronic device. 
     
     
       13. The system of  claim 9 , wherein the heat-generating component is at least one of a central processing unit (CPU) and a graphics-processing unit (GPU). 
     
     
       14. The system of  claim 9 , wherein the first thickness is created in the thermal stage using at least one of:
 a machining technique; 
 a rolling technique; 
 a skiving technique; 
 a continuous-machining technique; 
 a chemical-etching technique; 
 a coining technique; 
 a casting technique; and 
 a forging technique. 
 
     
     
       15. The system of  claim 9 , wherein the thermal stage comprises copper titanium. 
     
     
       16. The system of  claim 9 , wherein the heat pipe comprises copper. 
     
     
       17. A method for facilitating heat transfer in an electronic device, comprising:
 providing, in a thermal stage, a first thickness to accommodate a heat pipe in the electronic device and a second thickness that is greater than the first thickness to increase a spring force between a heat-generating component in the electronic device and a heat pipe; and 
 disposing the thermal stage along a thermal interface between the heat-generating component and the heat pipe. 
 
     
     
       18. The method of  claim 17 , further comprising:
 disposing a thermal interface material (TIM) between the heat-generating component and the thermal stage. 
 
     
     
       19. The method of  claim 17 , further comprising:
 joining the heat pipe to the thermal stage using a solder. 
 
     
     
       20. The method of  claim 17 , wherein the first thickness decreases an overall thickness of the electronic device. 
     
     
       21. The method of  claim 17 , wherein the first thickness is created in the thermal stage using at least one of:
 a machining technique; 
 a rolling technique; 
 a skiving technique; 
 a continuous-machining technique; 
 a chemical-etching technique; 
 a coining technique; 
 a casting technique; and 
 a forging technique. 
 
     
     
       22. The method of  claim 17 , wherein the thermal stage comprises copper titanium. 
     
     
       23. An electronic device, comprising:
 a heat-generating component, wherein the heat-generating component is a processor or a memory; 
 a heat pipe configured to conduct heat away from the heat-generating component; and 
 a thermal stage disposed along a thermal interface between the heat-generating component and the heat pipe, comprising: 
 a first thickness to accommodate the heat pipe, and 
 a second thickness that is greater than the first thickness to increase a spring force between the heat-generating component and the heat pipe. 
 
     
     
       24. The electronic device of  claim 23 , wherein the heat pipe is joined to the thermal stage using a solder. 
     
     
       25. The electronic device of  claim 23 , wherein the first thickness decreases an overall thickness of the electronic device. 
     
     
       26. The electronic device of  claim 23 , wherein the first thickness is created in the thermal stage using at least one of:
 a machining technique; 
 a rolling technique; 
 a skiving technique; 
 a continuous-machining technique; 
 a chemical-etching technique; 
 a coining technique; 
 a casting technique; and 
 a forging technique. 
 
     
     
       27. The electronic device of  claim 23 , wherein the thermal stage comprises copper titanium.

Description:
RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Application No. 61/657,534, entitled “Fasteners for Creating Thermal Gaps in Electronic Devices,” by inventors Brett Degner, Charles A. Schwalbach and William F. Leggett, filed 8 Jun. 2012. 
     This application also claims the benefit of U.S. Provisional Application No. 61/657,538, entitled “Dual-Thickness Thermal Stages in Electronic Devices,” by inventors Brett Degner, Patrick Kessler, Charles A. Schwalbach and Richard Tan, filed 8 Jun. 2012. 
    
    
     BACKGROUND 
     1. Field 
     The disclosed embodiments relate to techniques for facilitating heat transfer in electronic devices. More specifically, the disclosed embodiments relate to fasteners for creating thermal gaps and dual-thickness thermal stages in electronic devices. 
     2. Related Art 
     A modern portable electronic device typically contains a set of tightly packed components. For example, a laptop computer may include a keyboard, display, speakers, touchpad, battery, buttons, processor, memory, internal storage, and/or ports in an enclosure that is less than one inch thick, 8-11 inches long, and 12-16 inches wide. Moreover, most components in the portable electronic device generate heat, which must be dissipated to enable safe use of the portable electronic device and improve long-term reliability. For example, heat generated by components in a laptop computer may be transferred away from the components and out of the laptop computer to prevent damage to the components and increase user comfort and safety while operating the laptop computer. 
     However, heat-dissipation mechanisms for portable electronic devices generally involve the use of additional parts and/or materials. For example, heat sinks, cooling fans, heat pipes, thermal spreaders, and/or vents may be used to dissipate heat from components in a laptop computer. Such heat-dissipating parts and/or materials may take up space within the portable electronic devices and may add to the cost of the portable electronic devices. 
     Hence, space-efficient designs for portable electronic devices may be facilitated by more efficient and/or smaller heat-dissipation mechanisms in the portable electronic devices. 
     SUMMARY 
     The disclosed embodiments provide a system that facilitates heat transfer in an electronic device. The system includes a heat pipe configured to conduct heat away from a heat-generating component in the electronic device. The system also includes a thermal stage disposed along a thermal interface between the heat-generating component and the heat pipe, wherein the thermal stage applies a spring force between the heat-generating component and the heat pipe. The thermal stage includes a first thickness to accommodate the heat pipe and a second thickness that is greater than the first thickness to increase a spring force between the heat-generating component and the heat pipe. Finally, the system includes a set of fasteners configured to fasten the thermal stage to a surface within the electronic device and form a thermal gap between the heat pipe and an enclosure of the electronic device. 
     In some embodiments, the set of fasteners includes a screw. 
     In some embodiments, the thermal gap is formed by a head of the screw. 
     In some embodiments, the head includes an insulating material. For example, the head may be made of plastic and/or include a plastic cap. 
     In some embodiments, the surface is a printed circuit board (PCB) in the electronic device. 
     In some embodiments, the heat-generating component is a central processing unit (CPU) and/or a graphics-processing unit (GPU). 
     In some embodiments, the thermal interface also includes a thermal interface material (TIM) disposed between the heat-generating component and the thermal stage. 
     In some embodiments, the heat pipe is joined to the thermal stage using a solder. 
     In some embodiments, the first thickness decreases an overall thickness of the electronic device. 
     In some embodiments, the first thickness is created in the thermal stage using at least one of a machining technique, a rolling technique, a skiving technique, a continuous-machining technique, a chemical-etching technique, a coining technique, a casting technique, and a forging technique. 
     In some embodiments, the thermal stage includes copper titanium. 
     In some embodiments, the heat pipe includes copper. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  shows a bottom view of an electronic device in accordance with the disclosed embodiments. 
         FIG. 2  shows a cross-sectional view of a system for facilitating heat transfer in an electronic device in accordance with the disclosed embodiments. 
         FIG. 3  shows a sectional view of a system for facilitating heat transfer in an electronic device in accordance with the disclosed embodiments. 
         FIG. 4  shows a side view of a thermal stage in accordance with the disclosed embodiments. 
         FIG. 5  shows a wall in an electronic device in accordance with the disclosed embodiments. 
         FIG. 6  shows a rear view of a set of intake and exhaust zones in an electronic device in accordance with the disclosed embodiments. 
         FIG. 7  shows a cross-sectional view of an electronic device in accordance with the disclosed embodiments. 
         FIG. 8  shows a cross-sectional view of an electronic device in accordance with the disclosed embodiments. 
         FIG. 9  shows a gasket in an electronic device in accordance with the disclosed embodiments. 
         FIG. 10  shows a flexible portion of a gasket in accordance with the disclosed embodiments. 
         FIG. 11  shows a flexible portion of a gasket in accordance with the disclosed embodiments. 
         FIG. 12  shows a flow chart illustrating the process of facilitating heat transfer in an electronic device in accordance with the disclosed embodiments. 
         FIG. 13  shows a flow chart illustrating the process of facilitating heat transfer in an electronic device in accordance with the disclosed embodiments. 
         FIG. 14  shows a flow chart illustrating the process of assembling an electronic device in accordance with the disclosed embodiments. 
         FIG. 15  shows a portable electronic device in accordance with the disclosed embodiments. 
     
    
    
     In the figures, like reference numerals refer to the same figure elements. 
     DETAILED DESCRIPTION 
     The following description is presented to enable any person skilled in the art to make and use the embodiments, and is provided in the context of a particular application and its requirements. Various modifications to the disclosed embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments and applications without departing from the spirit and scope of the present disclosure. Thus, the present invention is not limited to the embodiments shown, but is to be accorded the widest scope consistent with the principles and features disclosed herein. 
     The data structures and code described in this detailed description are typically stored on a computer-readable storage medium, which may be any device or medium that can store code and/or data for use by a computer system. The computer-readable storage medium includes, but is not limited to, volatile memory, non-volatile memory, magnetic and optical storage devices such as disk drives, magnetic tape, CDs (compact discs), DVDs (digital versatile discs or digital video discs), or other media capable of storing code and/or data now known or later developed. 
     The methods and processes described in the detailed description section can be embodied as code and/or data, which can be stored in a computer-readable storage medium as described above. When a computer system reads and executes the code and/or data stored on the computer-readable storage medium, the computer system performs the methods and processes embodied as data structures and code and stored within the computer-readable storage medium. 
     Furthermore, methods and processes described herein can be included in hardware modules or apparatus. These modules or apparatus may include, but are not limited to, an application-specific integrated circuit (ASIC) chip, a field-programmable gate array (FPGA), a dedicated or shared processor that executes a particular software module or a piece of code at a particular time, and/or other programmable-logic devices now known or later developed. When the hardware modules or apparatus are activated, they perform the methods and processes included within them. 
       FIG. 1  shows a bottom view of an electronic device in accordance with the disclosed embodiments. More specifically,  FIG. 1  shows an electronic device, such as a laptop computer, with the bottom of the electronic device&#39;s enclosure removed. Within the electronic device, a number of components may be used to cool heat-generating components such as central-processing units (CPUs), graphics-processing units (GPUs), and/or video memory. 
     First, the electronic device may include a set of fans  102 - 104  for expelling heat generated by the heat-generating components outside the electronic device. Fans  102 - 104  may utilize a set of intake and exhaust vents along a wall  118  of the electronic device to draw in cooler air from outside the electronic device, circulate the air around the interior of the electronic device to dissipate heat from the heat-generating components, and expel the heated air out of the electronic device. 
     The electronic device may also include a heat pipe  106  that conducts heat away from one or more of the heat-generating components toward the flow of exhaust from fans  102 - 104 . For example, heat pipe  106  may be a sealed pipe of a thermally conductive material, such as copper, filled with a working fluid such as water, ethanol, acetone, sodium, and/or mercury in a partial vacuum. The working fluid may evaporate to vapor at the thermal interface with a heat-generating component closer to the center of heat pipe  106 , migrate to an end of heat pipe  106  that is cooled by a fan (e.g., fans  102 - 104 ), and condense back into liquid after the heat is removed by the fan. A sintered material (e.g., metal powder) in the interior of heat pipe  106  may then exert capillary pressure on the condensed liquid, conducting the liquid back to the heated portion of heat pipe  106  for subsequent transfer of heat away from the heat-generating component. 
     To further facilitate heat dissipation from the heat-generating component, a thermal stage  108  may apply a spring force between heat pipe  106  and the heat-generating component. For example, thermal stage  108  may be bonded to heat pipe  106  using a solder and fastened to a surface within the electronic device using a set of fasteners  110 - 116  to increase the amount of heat transferred along a thermal interface between the heat-generating component and heat pipe  106 . 
     In one or more embodiments, heat-dissipation mechanisms and/or components in the electronic device may include a number of characteristics and/or features that increase the transfer of heat away from the heat-generating components and/or facilitate efficient use of space within the electronic device. First, fasteners  110 - 116  may both fasten thermal stage  108  to a surface within the electronic device and create a thermal gap between heat pipe  106  and the enclosure of the electronic device, as discussed below with respect to  FIG. 2 . Second, thermal stage  108  may include two thicknesses to reduce an overall thickness of the electronic device while maintaining the spring force necessary to adequately cool the heat-generating component over which thermal stage  108  and heat pipe  106  are disposed, as described in further detail below with respect to  FIGS. 3-4 . 
     Third, wall  118  may include intake vents that are directed at a first angle toward one or more heat-generating components of the electronic device and exhaust vents directed at a second angle out of the electronic device to avoid a display of the electronic device. Wall  118  may also include one or more obstructed vents between the intake and exhaust vents, as well as mechanisms for reducing the temperature of hot spots in the enclosure of the electronic device. Wall  118  is described in further detail below with respect to  FIGS. 5-8 . 
     Finally, a set of gaskets  120 - 122  may provide thermal ducts between fans  102 - 104  and exhaust vents in wall  118  to prevent exhaust from recirculating inside the electronic device and reducing the effectiveness of heat dissipation from the heat-generating components. As discussed below with respect to  FIGS. 9-11 , gaskets  120 - 122  may include a rigid section that forms the duct, as well as a set of flexible sections that simplify assembly of heat pipe  106  on top of the rigid section and subsequently seal the duct around heat pipe  106 . 
       FIG. 2  shows a cross-sectional view of a system for facilitating heat transfer in an electronic device (e.g., the electronic device of  FIG. 1 ) in accordance with the disclosed embodiments. The system includes heat pipe  106  and thermal stage  108 , both of which are disposed over a heat-generating component  202  such as a CPU and/or GPU. 
     As shown in  FIG. 2 , thermal stage  108  may be disposed along a thermal interface in between heat pipe  106  and heat-generating component  202 . A thermal interface material (TIM)  214  may also be disposed within the thermal interface between heat-generating component  202  and thermal stage  108  to increase the thermal contact conductance between heat-generating component  202  and thermal stage  108 . 
     In one or more embodiments, the spring force of thermal stage  108  is used to increase thermal contact between heat-generating component  202  and heat pipe  106 . For example, thermal stage  108  may improve heat conduction between heat-generating component  202  and heat pipe  106  by reducing the thickness and, in turn, the thermal resistance of TIM  214 . As a result, thermal stage  108  may be made of a material with a high thermal conductivity and spring constant, such as copper titanium. 
     To provide thermal contact between heat-generating component  202  and heat pipe  106 , heat pipe  106  may be joined to thermal stage  108  using a solder  216 - 218 , and thermal stage  108  may be fastened to a surface  208  within the electronic device using a set of fasteners  204 - 206  (e.g., fasteners  110 - 116  of  FIG. 1 ). For example, fasteners  204 - 206  may include one or more screws that fasten a set of wings of thermal stage  108  to a printed circuit board (PCB) containing heat-generating component  202 . Fasteners  204 - 206  and thermal stage  108  may thus apply downward force onto heat-generating component  202  and increase the thermal coverage of heat-generating component  202  by heat pipe  106 . 
     Fasteners  204 - 206  may additionally form a thermal gap  220  between heat pipe  106  and an enclosure  222  of the electronic device. Continuing with the above example, screws used to provide fasteners  204 - 206  may have tall heads  210 - 212  that provide a 0.5 mm-0.8 mm thermal gap  220  and/or plenum through which air may flow to further cool heat-generating component  202  and/or other heat-generating components in the electronic device. Alternatively, other types of fasteners  204 - 206  may be used to provide thermal gap  220 , including clips, barbed fasteners, bolts, clamps, pins, pegs, and/or clasps. 
     Thermal gap  220  may also prevent heat pipe  106  from thermally contacting enclosure  222  if the electronic device is dropped and/or impacts another object. For example, fasteners  204 - 206  may be placed around heat-generating component  202  if heat-generating component  202  is located relatively far from an attachment point of a metal enclosure  222  to ensure that trampolining in enclosure  222  does not cause heat pipe  106  to transfer heat to enclosure  222  and/or a surface contacting enclosure  222 . Fasteners  204 - 206  may further be attached to a surface (e.g., the center of a PCB) with lower stiffness so that the impact does not damage heat-generating component  202  and/or other nearby components. 
     However, the proximity of fasteners  204 - 206  to enclosure  222  may result in physical contact between fasteners  204 - 206  and enclosure  222 . For example, fasteners  204 - 206  may touch enclosure  222  if fasteners  204 - 206  are designed to be intimate with enclosure  222  and/or if fasteners  204 - 206  are brought in contact with enclosure  222  during impact between enclosure  222  and a hard object. 
     As a result, fasteners  204 - 206  may include an insulating material to prevent fasteners  204 - 206  from heating enclosure  222  in the event of physical contact between the fasteners  204 - 206  and enclosure  222 . For example, fasteners  204 - 206  may be made of plastic to reduce thermal conduction between fasteners  204 - 206  and enclosure  222 . Consequently, fasteners  204 - 206  may improve thermal contact between heat-generating component  202  and heat pipe  106 , provide thermal gap  220  as a channel for airflow and/or heat dissipation from heat-generating component  202  and/or heat pipe  106 , and facilitate safe operation of the electronic device by thermally insulating enclosure  222  from heat-generating component  202  and/or heat pipe  106 . 
       FIG. 3  shows a sectional view of a system for facilitating heat transfer in an electronic device in accordance with the disclosed embodiments. As mentioned above, the system may include heat pipe  106  and thermal stage  108 , both of which are disposed over a heat-generating component  302  (e.g., a CPU). Heat pipe  106  may be soldered to thermal stage  108 , and a set of wings  304 - 306  of thermal stage  108  may be fastened to a surface within the electronic device to apply a spring force to heat-generating component  302 . For example, the fastening of wings  304 - 306  that are angled upward to a PCB containing heat-generating component  302  may apply a downward force onto heat-generating component  302  and increase the thermal contact conductance between heat-generating component  302  and heat pipe  106 . 
       FIG. 4  shows a side view of thermal stage  108  in accordance with the disclosed embodiments. Thermal stage  108  may include a number of regions  404 - 406  with different thicknesses. In particular, region  402  may be of a first thickness, and regions  404 - 406  may be of a second thickness that is greater than the first thickness. 
     The first and/or second thicknesses may be created in thermal stage  108  using a number of techniques. For example, a machining technique may be used to form a trough in a material (e.g., copper titanium) of uniform stock thickness. Similarly, a profile corresponding to the first thickness may also be formed in raw stock using a rolling technique. The first thickness may further be created by removing material from uniform stock using a skiving technique, continuous machining technique, and/or chemical-etching technique. A forging and/or coining technique may be used to press the first thickness into uniform stock, or a casting technique may be used to form the first and second thicknesses from a mold. 
     As mentioned above, the first thickness may accommodate a heat pipe (e.g., heat pipe  106  of  FIG. 1 ). For example, the first thickness may form a notch and/or groove within which the heat pipe may be placed to reduce an overall thickness of the electronic device containing thermal stage  108  and the heat pipe. On the other hand, the second thickness may increase a spring force between a heat-generating component and the heat pipe, allowing for better thermal transfer between the heat-generating component (e.g., a high-power CPU) and the heat pipe. For example, the second thickness may be used in the wings (e.g., wings  304 - 306  of  FIG. 3 ) of thermal stage  108  to increase the downward force applied by thermal stage  108  and/or a set of fasteners (e.g., fasteners  110 - 116  of  FIG. 1 ) onto the top of the heat-generating component. Consequently, the first and second thicknesses may facilitate both efficient use of space within the electronic device and increased cooling of the heat-generating component by the heat pipe. 
       FIG. 5  shows wall  118  in accordance with the disclosed embodiments. Wall  118  may be a rear wall of an electronic device, such as a laptop computer. The rear wall may be integrated into a top case of the laptop computer to reduce the number of seams and/or components in the laptop computer&#39;s enclosure. For example, instead of creating wall  118  as a separate part and subsequently joining wall  118  to the top case, wall  118  may be machined out of the top case. In turn, the reduced number of seams and/or components in the enclosure may mitigate electromagnetic interference caused by the enclosure and/or improve the rigidity and/or height tolerance of the enclosure. 
     As shown in  FIG. 5 , wall  118  includes an intake zone  502  and two exhaust zones  504 - 506 . Intake zone  502  includes a set of intake vents around the center of wall  118  that allow a set of fans (e.g., fans  102 - 104  of  FIG. 1 ) to draw cooler air from the exterior of the electronic device into the electronic device. The fans may then circulate the air inside a set of plenums and/or thermal gaps (e.g., thermal gap  220  of  FIG. 2 ) within the electronic device and expel the heated air out of the electronic device through a set of exhaust vents in exhaust zones  504 - 506  on either side of intake zone  502 . As discussed in further detail below with respect to  FIGS. 7-8 , the intake vents may be directed at a first angle toward one or more heat-generating components of the electronic device, and the exhaust vents may be directed at a second angle out of the electronic device. 
       FIG. 6  shows a rear view of a set of intake and exhaust zones  502 - 506  of an electronic device in accordance with the disclosed embodiments. As described above, intake zone  502  may include a set of intake vents that are used by fans to draw in air from outside the electronic device, while each exhaust zone  504 - 506  may include a set of exhaust vents that are used by the fans to expel heated air out of the electronic device. 
     In addition, a set of obstructed vents  602 - 608  may separate intake zone  502  from exhaust zones  504 - 506 . Air flow from vents  602 - 608  may be blocked from the inside of the electronic device by a portion of a duct formed by a gasket in the electronic device, as described below with respect to  FIG. 10 . Such obstruction of substantially evenly spaced openings in intake and exhaust zones  502  and exhaust zones  504 - 506  may maintain the cosmetic continuity of the vents in intake and exhaust zones  502 - 506 , reduce electromagnetic interference from the enclosure of the electronic device, and facilitate heat dissipation in the electronic device by separating the intake and exhaust flows passing through intake and exhaust zones  502 - 506 , respectively. 
       FIG. 7  shows a cross-sectional view of an electronic device in accordance with the disclosed embodiments. More specifically,  FIG. 7  shows a cross-sectional view of an exhaust vent  702  from an exhaust zone (e.g., exhaust zones  504 - 506  of  FIG. 5 ) in a wall (e.g., wall  118  of  FIG. 1 ) of the electronic device. Air from the interior of the electronic device may be moved by a fan (e.g., fans  102 - 104  of  FIG. 1 ) across heat pipe  106  and a heat sink  712 , where the air is heated and expelled as exhaust out of exhaust vent  702 . 
     In addition, two flows  704 - 706  of exhaust out of vent  702  may be created by a clutch barrel  710  connecting a display of the electronic device (e.g., a laptop computer) to the bottom portion of the electronic device. Flow  704  may exit the electronic device along the bottom of clutch barrel  710 , while flow  706  may exit the electronic device over the top of clutch barrel  710 . To prevent exhaust from changing the white point of and/or accelerating degradation in the display, exhaust vent  702  may be directed at an angle out of the electronic device so that exhaust flows  704 - 706  avoid the display and/or do not create a large temperature gradient across the display. If the display is closed over the bottom portion of the electronic device, flow  706  may cease, and all exhaust may be expelled out of vent  702  through an air gap between the bottom of the electronic device and clutch barrel  710 . 
     Those skilled in the art will appreciate that exhaust flowing out of exhaust vent  702  may also heat material in the wall near exhaust vent  702  and create a hot spot in the enclosure of the electronic device. As a result, a T-cut  708  may be made in the material to reduce the thickness of the material and, in turn, the transfer of heat through the material. At the same time, the thickness of the material between exhaust vent  702  and one or more intake vents in the electronic device may be maintained to facilitate lateral conduction of heat from exhaust vent  702  to the intake vent(s), thus further reducing the temperature of the hot spot. Consequently, the relatively large size of exhaust vent  702 , T-cut  708 , and/or ridges at the bottom of exhaust vent  702  may provide a lightweight structure with thermally minimal spars, a reduced conduction path to both the top and bottom enclosures of the electronic device, and a lateral conduction path between the exhaust and intake zones in the wall. 
       FIG. 8  shows a cross-sectional view of an electronic device in accordance with the disclosed embodiments. In particular,  FIG. 8  shows a cross-sectional view of an intake vent  802  from an intake zone (e.g., intake zone  502  of  FIG. 5 ) in a wall (e.g., wall  118  of  FIG. 1 ) of the electronic device. Intake vent  802  may allow cooler air from outside the electronic device to be drawn into the electronic device by a fan (e.g., fans  102 - 104  of  FIG. 1 ) and circulated within the electronic device before being expelled as exhaust out of one or more exhaust vents (e.g., exhaust vent  702  of  FIG. 7 ) in the wall. 
     Two flows  804 - 806  of air may pass through intake vent  802  while a display of the electronic device (e.g., a laptop computer) is open. Flow  804  may enter the electronic device along the bottom of a clutch barrel  810  connecting the display to the bottom of the electronic device, while flow  806  may enter the electronic device from the top of clutch barrel  810 . If the display is closed over the bottom of the electronic device, flow  806  may cease, and all air drawn in through intake vent  802  may flow  804  from an air gap between the bottom of the electronic device and clutch barrel  810 . 
     Moreover, intake vent  802  may be directed at an upward angle toward a heat-generating component  808  of the electronic device to facilitate heat dissipation from heat-generating component  808 . For example, intake vent  802  may channel air over the top of a PCB containing video memory to cool the video memory and/or other heat-generating components at the top of the PCB. As a result, air passing through intake vent  802  may dissipate heat from heat-generating component  808  better than air passing through an intake vent that is not angled upwards into the interior of the electronic device. 
       FIG. 9  shows a gasket  902  (e.g., gaskets  120 - 122  of  FIG. 1 ) in an electronic device in accordance with the disclosed embodiments. As mentioned above, gasket  902  may form a thermal duct between a fan  910  and a set of exhaust vents in wall  118  to prevent exhaust from recirculating inside the electronic device and reducing the effectiveness of heat dissipation from heat-generating components in the electronic device. 
     As shown in  FIG. 9 , gasket  902  may include three portions  904 - 908 . A rigid portion  904  may be disposed around a bottom of heat pipe  106  to form the duct between fan  910  and wall  118 . Two flexible portions  904 - 906  may then be bonded to rigid portion  904  so that gasket  902  is manufactured as a single component instead of multiple components that require multiple steps to assemble into gasket  902 . For example, flexible portions  904 - 906  may be made of a rubber that is bonded to a rigid portion  904  made of plastic using an overmolding technique. 
     Portion  906  may be a flap that is open during assembly of heat pipe  106  in the electronic device to allow heat pipe  106  to be placed over portions  904  and  908 . Portion  906  may then be closed over heat pipe  106  and portions  904  and  908  to seal the duct around heat pipe  106  after the assembly. Portions  904 - 906  may further seal the duct around fan  910 , a bottom enclosure (not shown) of the electronic device, a top enclosure  912  of the electronic device, and/or exhaust vents in wall  118 . For example, portion  906  may fold over portions  904  and  908  to seal along the top of fan  910 , the top and/or sides of heat pipe  106 , and/or the bottom enclosure. On the other hand, portion  908  may be bonded to one or more edges of portion  904  and seal along the bottom of fan  910 , the bottom and/or sides of heat pipe  106 , top enclosure  912 , and/or wall  118 . Gasket  902  may also include an additional flexible portion  914  that seals the duct along wall  118 . Alternatively, portion  914  may be provided by a separate component (e.g., a gasket) disposed between gasket  902  and wall  118 . 
       FIG. 10  shows flexible portion  906  of a gasket (e.g., gasket  902  of  FIG. 9 ) in accordance with the disclosed embodiments. As mentioned above, portion  906  includes a flap that is open during assembly of heat pipe  106  in the electronic device. For example, the electronic device may be assembled by placing the gasket into the top enclosure of the electronic device with portion  906  open over wall  118 . After the gasket is placed into the top enclosure of the electronic device, a part of rigid portion  904  may obstruct one or more vents in wall  118  to separate the intake and exhaust zones of wall  118 . Next, fan  910  may be placed next to the gasket, and heat pipe  106  may be placed on top of rigid portion  904  and/or a second flexible portion (e.g., portion  908  of  FIG. 9 ) of the gasket. 
       FIG. 11  shows flexible portion  906  of a gasket (e.g., gasket  902  of  FIG. 9 ) in accordance with the disclosed embodiments. As shown in  FIG. 11 , portion  906  may be closed over heat pipe  106 , rigid portion  904 , and the second flexible portion after heat pipe  106  is assembled in the electronic device. The bottom enclosure of the electronic device may then be placed over the gasket to create a compression seal around heat pipe  106 , fan  910 , one or more exhaust vents of wall  118 , and/or the top enclosure of the electronic device. In addition, the insulating materials used in the gasket may restrict heat transfer between the exhaust and the enclosure of the electronic device, thus facilitating safe operation of the electronic device. 
       FIG. 12  shows a flow chart illustrating the process of facilitating heat transfer in an electronic device in accordance with the disclosed embodiments. In one or more embodiments, one or more of the steps may be omitted, repeated, and/or performed in a different order. Accordingly, the specific arrangement of steps shown in  FIG. 12  should not be construed as limiting the scope of the embodiments. 
     Initially, a first thickness to accommodate a heat pipe in the electronic device and a second thickness that is greater than the first thickness to increase a spring force between the heat-generating component and the heat pipe are provided in a thermal stage (operation  1202 ). The thermal stage may be made of copper titanium and/or another material with a high thermal conductivity and/or spring constant. The first and/or second thicknesses may be created using a machining technique, a rolling technique, a skiving technique, a forging technique, a coining technique, a chemical etching technique, and/or a casting technique. 
     Next, a TIM is disposed between the heat-generating component and the thermal stage (operation  1204 ). For example, the TIM may be applied to a surface of the heat-generating component and/or the thermal stage. The thermal stage is then disposed along a thermal interface between the heat-generating component and the heat pipe (operation  1206 ), and the heat pipe is joined to the thermal stage using a solder (operation  1208 ). For example, the thermal stage may be placed over the heat-generating component, and the heat pipe may be placed over the thermal stage and soldered to the thermal stage. 
     The thermal stage is also fastened to a surface within the electronic device using a set of fasteners (operation  1210 ), and the set of fasteners is used to form a thermal gap between the heat pipe and the enclosure of the electronic device (operation  1212 ). For example, the fasteners may include screws with tall heads that form a plenum between the heat pipe and enclosure through which air may flow to further dissipate heat from the heat-generating component. The screws may also separate the heat pipe from the enclosure, thus preventing the heat pipe from transmitting large amounts of heat through the enclosure. Similarly, the heads of the screws may include an insulating material such as plastic to prevent the heat-generating component from thermally contacting the enclosure if the enclosure touches the screws&#39; heads (e.g., as a result of impact between the electronic device and a hard surface and/or by design). 
       FIG. 13  shows a flow chart illustrating the process of facilitating heat transfer in an electronic device in accordance with the disclosed embodiments. In one or more embodiments, one or more of the steps may be omitted, repeated, and/or performed in a different order. Accordingly, the specific arrangement of steps shown in  FIG. 13  should not be construed as limiting the scope of the embodiments. 
     Initially, a wall of the electronic device that includes an intake zone containing a set of intake vents directed at a first angle toward one or more heat-generating components of the electronic device and an exhaust zone containing a set of exhaust vents directed at a second angle out of the electronic device is provided (operation  1302 ). For example, the wall may be a rear wall that is integrated into a top case of a laptop computer. The first angle may facilitate the cooling of components at the top of a PCB in the laptop computer, while the second angle may direct exhaust out of the laptop computer so that the exhaust avoids the display of the laptop computer. 
     Next, one or more vents between the intake zone and exhaust zone are obstructed (operation  1304 ). The vents may be obstructed by a portion of a duct between a fan and the exhaust zone and/or another component in the electronic device. The obstructed vents may maintain the cosmetic continuity of the electronic device while separating the intake and exhaust flows passing through the intake and exhaust zones. 
     Material adjacent to the exhaust vent may also be removed to reduce a temperature of a hot spot in the material during the transfer of exhaust out of the electronic device (operation  1306 ). For example, the material may be removed using a T-cut to reduce the amount of heat conducted through the material to the outside of the electronic device&#39;s enclosure. The temperature of the hotspot may further be reduced by maintaining the thickness of the material between the exhaust vent and one or more intake vents (operation  1308 ) in the electronic device. For example, the thickness of material separating the exhaust vent from an intake vent to the side of the exhaust vent may be maintained to facilitate lateral conduction of heat from the exhaust vent to the intake vent. 
       FIG. 14  shows a flow chart illustrating the process of assembling an electronic device in accordance with the disclosed embodiments. In one or more embodiments, one or more of the steps may be omitted, repeated, and/or performed in a different order. Accordingly, the specific arrangement of steps shown in  FIG. 14  should not be construed as limiting the scope of the embodiments. 
     First, a gasket containing a rigid portion forming a duct between a fan and exhaust vent of the electronic device, a first flexible portion containing a flap, and a second flexible portion bonded to one or more edges of the rigid portion is placed within an enclosure of the electronic device (operation  1402 ). For example, the gasket may be placed inside a top enclosure of the electronic device so that one end of the gasket is flush with a wall (e.g., wall  118  of  FIG. 1 ) containing the exhaust vent, and a fan may be installed in the electronic device so that the other end of the gasket is flush with the fan. The rigid portion may be made of plastic, while the first and second flexible portions may be made of a rubber that is bonded to the rigid portion using an overmolding technique. 
     Next, a heat pipe is disposed over the rigid portion and second flexible portion while the flap is open (operation  1404 ). For example, the heat pipe may be assembled in the electronic device so that the heat pipe rests on top of the rigid portion and second flexible portion while the flap is open over the wall. 
     Finally, the flap is closed over the heat pipe, the rigid portion, and the second flexible portion to seal the duct around the heat pipe (operation  1406 ). The first and second flexible portions may also seal the duct around the fan, the bottom enclosure of the electronic device, the top enclosure of the electronic device, and/or the exhaust vent. The gasket may thus prevent recirculation of exhaust within the electronic device, simplify the assembly of the heat pipe and/or electronic device, and/or insulate the enclosure of the electronic device from the heated exhaust. 
     The above-described heat transfer mechanisms can generally be used in any type of electronic device. For example,  FIG. 15  illustrates a portable electronic device  1500  which includes a processor  1502 , a memory  1504  and a display  1508 , which are all powered by a battery  1506 . Portable electronic device  1500  may correspond to a laptop computer, tablet computer, mobile phone, personal digital assistant (PDA), portable media player, digital camera, and/or other type of battery-powered electronic device. To cool heat-generating components in portable electronic device  1500 , portable electronic device  1500  may include a heat pipe that conducts heat away from the heat-generating components and/or one or more fans that expel the heat out of portable electronic device  1500 . 
     Portable electronic device  1500  may also include a thermal stage disposed along a thermal interface between a heat-generating component and the heat pipe. The thermal stage may include a first thickness to accommodate the heat pipe and a second thickness that is greater than the first thickness to increase the spring force between the heat-generating component and the heat pipe. The thermal stage may also be fastened to a surface within portable electronic device  1500  by a set of fasteners that form a thermal gap between the heat pipe and the enclosure of portable electronic device  1500 . 
     To further facilitate cooling of the heat-generating components, a wall of portable electronic device  1500  may include an intake zone containing a set of intake vents directed at a first angle toward one or more of the heat-generating components. The wall may also include an exhaust zone containing a set of exhaust vents directed at a second angle out of the electronic device (e.g., to avoid a display of the electronic device). One or more vents may be obstructed between the intake and exhaust zones to separate the intake and exhaust zones. In addition, the temperature of a hot spot near an exhaust vent may be reduced by removing material adjacent to the exhaust vent and/or maintaining a thickness of the material between the exhaust vent and one or more intake vents. 
     Finally, a gasket may prevent the recirculation of exhaust inside the electronic device. The gasket may include a rigid portion that forms a duct between a fan and an exhaust vent. The gasket may also include a first flexible portion bonded to the rigid portion, as well as a second flexible portion bonded to one or more edges of the rigid portion. The first flexible portion may be a flap that is open during assembly of the heat pipe in the electronic device and closed over the heat pipe and the rigid portion to seal the duct around the heat pipe after the assembly. The first and second flexible portions may further seal the duct around the fan, the bottom enclosure of the electronic device, the top enclosure of the electronic device, and/or the exhaust vent. 
     The foregoing descriptions of various embodiments have been presented only for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the forms disclosed. Accordingly, many modifications and variations will be apparent to practitioners skilled in the art. Additionally, the above disclosure is not intended to limit the present invention.

Metadata:
Filing Date: 20120913
Publication Date: 20150310
Grant Date: 20150310
Priority Date: 20120608
Inventors: DEGNER BRETT W.
KESSLER PATRICK
SCHWALBACH CHARLES A.
TAN RICHARD H.
LEGGETT WILLIAM F.
Assignee: APPLE INC
CPC Classifications: [{"code": "F28D15/0275", "inventive": true, "first": false, "tree": "[]"}, {"code": "F28D15/0233", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/20", "inventive": true, "first": true, "tree": "[]"}, {"code": "F28D15/0233", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "G06F1/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "F28D15/0275", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 49715146