PATENT DOCUMENT

Publication Number: US-10881028-B1
Application Number: US-201916502059-A
Country: US
Kind Code: B1

Title: Efficient heat removal from electronic modules

Abstract:
An electronic module includes an operational subunit, having upper, lower and lateral surfaces, and including one or more electronic components, which are adjacent to the lower surface of the operational subunit and generate heat when the module is in operation. A heat sink is disposed in proximity to the lower surface of the operational subunit. A heat spreader, including a continuous sheet of a heat-conducting material, is folded to wrap around the operational subunit so that a lower side of the sheet is interposed between the lower surface of the operational subunit and the heat sink and a lateral side of the sheet extends around at least one of the lateral surfaces of the operational subunit.

Claims:
The invention claimed is: 
     
       1. An electronic module, comprising:
 an operational subunit, having upper, lower and lateral surfaces, and comprising one or more electronic components, which are adjacent to the lower surface of the operational subunit and generate heat when the module is in operation, 
 wherein the operational subunit comprises an optoelectronic module having a window opening through the upper surface; 
 a heat sink, disposed in proximity to the lower surface of the operational subunit; and 
 a heat spreader, comprising a continuous sheet of a heat-conducting material, which is folded to wrap around the operational subunit so that a lower side of the sheet is interposed between the lower surface of the operational subunit and the heat sink and a lateral side of the sheet extends around at least one of the lateral surfaces of the operational subunit, and an upper side of the sheet overlies the upper surface of the operational subunit and has an opening through which the window is exposed. 
 
     
     
       2. The module according to  claim 1 , wherein the heat-conducting material comprises graphite. 
     
     
       3. The module according to  claim 1 , wherein the heat-conducting material comprises a flexible foil. 
     
     
       4. The module according to  claim 1 , wherein the one or more electronic components comprise a light source. 
     
     
       5. The module according to  claim 1 , wherein the sheet of the heat-conducting material is folded into a U-shape, which wraps around the operational subunit. 
     
     
       6. An electronic device, comprising:
 a backplate; 
 the module according to  claim 1 , which is mounted in the device with the heat sink in thermal contact with the backplate, such that a first part of the heat generated in the operational subunit is conducted through the heat spreader and heat sink to the backplate; and 
 a cover, which fits over the backplate and contains the module, such that a second part of the heat generated in the operational subunit is dissipated from the upper side of the heat spreader through the cover. 
 
     
     
       7. A method for producing an electronic module, the method comprising:
 providing an operational subunit, having upper and lower surfaces, and comprising one or more electronic components, which are adjacent to the lower surface of the operational subunit and generate heat when the module is in operation, 
 wherein the operational subunit comprises an optoelectronic module having a window opening through the upper surface; 
 wrapping a heat spreader, comprising a continuous sheet of a heat-conducting material, around the operational subunit so that a lower side of the sheet covers the lower surface of the operational subunit, and an upper side of the sheet overlies the upper surface of the operational subunit and has an opening through which the window is exposed; and 
 fixing the lower side of the sheet to a heat sink. 
 
     
     
       8. The method according to  claim 7 , wherein the heat-conducting material comprises graphite. 
     
     
       9. The method according to  claim 7 , wherein the heat-conducting material comprises a flexible foil. 
     
     
       10. The method according to  claim 7 , wherein the one or more electronic components comprise a light source. 
     
     
       11. The method according to  claim 7 , wherein wrapping the heat spreader comprises folding the sheet of the heat-conducting material so that a lateral side of the sheet extends around at least one of the lateral surfaces of the operational subunit, and the upper side of the sheet overlies the upper surface of the operational subunit. 
     
     
       12. The method according to  claim 11 , wherein the sheet of the heat-conducting material is folded into a U-shape, which wraps around the operational subunit. 
     
     
       13. The method according to  claim 11 , and comprising:
 mounting the module in a device with the heat sink in thermal contact with a backplate of the device, such that a first part of the heat generated in the operational subunit is conducted through the heat spreader and heat sink to the backplate; and 
 fitting a cover over the backplate and contains the module, such that a second part of the heat generated in the operational subunit is dissipated from the upper side of the heat spreader through the cover.

Description:
FIELD OF THE INVENTION 
     The present invention relates generally to design and production of electronic modules, and particularly to methods and components for enhancing heat dissipation from such modules. 
     BACKGROUND 
     Mobile electronic devices, such as smartphones, are packed densely with electronic modules. All of these modules generate heat, and some—such as a camera module with an integrated illumination source—can generate a great deal of heat in a small volume. Careful thermal design is needed in order to ensure that temperatures within the device do not exceed designed operating limits. 
     For this reason, high-power electronic modules are commonly mounted on a heat sink, comprising a material with high thermal conductivity and high thermal mass, which absorbs heat from the components of the module and transfers the heat efficiently to a fluid medium (such as the air). When the heat source within the electronic module is small and has a high heat-flux density, a heat spreader may be used to increase the rate of heat transfer between the heat source and the heat sink. The heat spreader comprises a sheet or block of material with high thermal conductivity, which absorbs heat in a small area from the heat source and spreads the heat over a larger area, at least part of which is in contact with the heat sink. 
     SUMMARY 
     Embodiments of the present invention that are described hereinbelow provide electronic modules with improved heat dissipation, and well as devices and methods for use in producing such modules. 
     There is therefore provided, in accordance with an embodiment of the invention, an electronic module, which includes an operational subunit, having upper, lower and lateral surfaces, and including one or more electronic components, which are adjacent to the lower surface of the operational subunit and generate heat when the module is in operation. A heat sink is disposed in proximity to the lower surface of the operational subunit. A heat spreader, including a continuous sheet of a heat-conducting material, is folded to wrap around the operational subunit so that a lower side of the sheet is interposed between the lower surface of the operational subunit and the heat sink and a lateral side of the sheet extends around at least one of the lateral surfaces of the operational subunit. 
     In a disclosed embodiment, the heat-conducting material comprises graphite. Additionally or alternatively, the heat-conducting material comprises a flexible foil. 
     In one embodiment, the one or more electronic components comprise a light source. 
     In some embodiments, the sheet of the heat-conducting material is folded so that an upper side of the sheet overlies the upper surface of the operational subunit. In a disclosed embodiment, the sheet of the heat-conducting material is folded into a U-shape, which wraps around the operational subunit. 
     There is also provided, in accordance with an embodiment of the invention, an electronic device, including a backplate and the module as described above, which is mounted in the device with the heat sink in thermal contact with the backplate, such that a first part of the heat generated in the operational subunit is conducted through the heat spreader and heat sink to the backplate. A cover fits over the backplate and contains the module, such that a second part of the heat generated in the operational subunit is dissipated from the upper side of the heat spreader through the cover. 
     There is additionally provided, in accordance with an embodiment of the invention, a method for producing an electronic module. The method includes providing an operational subunit, having upper and lower surfaces, and including one or more electronic components, which are adjacent to the lower surface of the operational subunit and generate heat when the module is in operation. A heat spreader, including a continuous sheet of a heat-conducting material, is wrapped around the operational subunit so that a lower side of the sheet covers the lower surface of the operational subunit, and an upper side of the sheet overlies the upper surface of the operational subunit. The lower side of the sheet is fixed to a heat sink. 
     In some embodiments, wrapping the heat spreader includes folding the sheet of the heat-conducting material so that an upper side of the sheet overlies the upper surface of the operational subunit. In one embodiment, the sheet of the heat-conducting material is folded into a U-shape, which wraps around the operational subunit. 
     The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which: 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is schematic pictorial view of a mobile electronic device, in accordance with an embodiment of the invention; 
         FIGS. 2A and 2B  are schematic upper and lower pictorial views, respectively, of an electronic module incorporated in the device of  FIG. 1 , in accordance with an embodiment of the invention; 
         FIG. 3  is a schematic sectional view of the electronic module of  FIGS. 2A /B, taken along the line labeled III-III in  FIG. 1 ; 
         FIG. 4  is a schematic pictorial view of a heat spreader, in accordance with an embodiment of the invention; 
         FIG. 5A  is a schematic sectional view of the electronic module of  FIGS. 2A /B, taken along the line labeled V-V in  FIG. 1 ; and 
         FIG. 5B  schematically shows thermal paths in the sectional view of  FIG. 5A . 
     
    
    
     DETAILED DESCRIPTION OF EMBODIMENTS 
     Mobile devices, such as smartphones, contain electronic components that generate substantial amounts of heat relative to their small volume. As an example of such components, a camera module in the device may comprise a high-power light source, such as a light-emitting diode (LED) or laser diode. This heat must be dissipated effectively to ensure proper device operation, as well as to avoid shortened device lifetime that can occur due to overheating. Severe overheating can happen very suddenly when the thermal path through which heat is dissipated from the heat-generating module is interrupted, for example due to a mechanical fault. 
     Embodiments of the present invention that are described herein address these problems by providing a module design that supports redundant thermal paths. Specifically, in the disclosed embodiments, a novel heat spreader is wrapped around an electronic module so as to evacuate heat from multiple different surfaces of the module. The heat spreader thus creates multiple thermal paths, one of which may operate by conduction of heat to a heat sink, for example, while another path operates by convection and/or conduction through another part of the electronic device in which the module is installed. The creation of multiple thermal paths in this manner provides more effective heat dissipation, so that the normal operating temperature of the module can be reduced, and also offers a failsafe against rapid overheating in the event that one of the thermal paths is broken. 
     In the disclosed embodiments, an electronic module comprises an operational subunit, which contains one or more electronic components that generate heat when the module is in operation. These components are assumed to be adjacent to the lower surface of the operational subunit, which is positioned in proximity to a heat sink. A heat spreader, comprising a continuous sheet of a heat-conducting material, wraps around the operational subunit, so that a lower side of the sheet is interposed between the lower surface of the operational subunit and the heat sink, while a lateral side of the sheet extends around at least one of the lateral surfaces of the operational subunit. In some embodiments, the heat spreader sheet is folded, possibly into a U-shape, so that the upper side of the sheet overlies the upper surface of the operational subunit. 
     The terms “upper” and “lower” are used arbitrarily, for the sake of convenience in the present description and in the claims, to identify the opposing sides of the electronic module from which heat is to be removed. Typically, such modules will operate in any orientation, meaning that in use, the “lower” side may be facing upward or sideways. 
     In some embodiments of the present invention, the heat spreader comprises a graphite sheet, which is a good heat conductor and has the added advantage that it conducts heat well through folds in the sheet. Additionally or alternatively, the heat spreader may comprise a flexible foil. 
       FIG. 1  is schematic pictorial view of a mobile electronic device  20 , in accordance with an embodiment of the invention. Device  20  comprises a case  22 , containing components such as communication circuits, a display and a battery (not shown in the figures), overlaid by a backplate (shown in  FIGS. 3 and 5 ). An electronic module is mounted in device  20 , and is connected to an auxiliary circuit board  28  in the pictured example. A cover  24  fits over the backplate of case  22  and contains module  26 . 
       FIGS. 2A and 2B  are schematic upper and lower pictorial views, respectively, of electronic module  26 , in accordance with an embodiment of the invention. (Again, the terms “upper” and “lower” are used arbitrarily, for convenience of description.) In this example, module  26  is an optoelectronic module, such as a camera with a built-in illumination source. For this purpose, a window  30  opens through the upper surface of module  26 . The window is surrounded by the upper side of a heat spreader  32 , which is described in greater detail hereinbelow. The lower side of the heat spreader is covered by a heat sink  34 , comprising a block of a metal, such as copper, or suitable ceramic material. A connector  36  is used to connect the electronic components in module  26  to auxiliary circuit board  28 . 
       FIG. 3  is a schematic sectional view of electronic module  26 , taken along the line labeled III-III in  FIG. 1 . Module  26  comprises an operational subunit  38 , comprising one or more electronic components  44 , which generate heat when the module is in operation. For example, operational subunit  38  may be an imaging subunit including one or more light sources, optics, and an image sensor within a housing. (The principles of the present embodiment are applicable to substantially any subunit of this sort, in which electrical components generate heat.) Components  44  are mounted on a flexible printed circuit (which extends out to connector  36 ), in a location adjacent to the lower surface of the operational subunit. The internal details of operational subunit  38  are not relevant to an understanding of the present invention and are omitted for the sake of simplicity. 
     Heat spreader  32  is folded to wrap around operational subunit  38  (as can been seen more clearly in  FIG. 5A ). The lower side of the heat spreader is located below components  44 , interposed between the lower surface of operational subunit  38  and heat sink  34 . In the pictured example, heat spreader  32  is connected to heat sink  34  by a thermal pad  48 , comprising a suitable thermally-conductive gel or epoxy, for example, in order to ensure good thermal contact between the heat spreader and the heat sink. Heat sink  34  is in thermal contact with a backplate  40  of device  20 , while backplate  40  is fixed to case  22  by a suitable adhesive  42 . Backplate  40  comprises a sheet of aluminum, for example, or another material with good thermal conductivity. A flexible printed circuit  50  (also seen more clearly in  FIG. 5 ) connects module  26  to the components in case  22  (but these components and connections are beyond the scope of the present description). 
     A bracket  52  is fixed to the upper surface of operational subunit  38 , for example by a thin layer of a suitable adhesive  54 . The upper side of heat spreader  32  is folded over and fixed to the upper surface of bracket  52 . Cover  24  is then fitted over bracket  52 , with window  30  exposed through a corresponding opening in cover  24 . 
       FIG. 4  is a schematic pictorial view of heat spreader  32 , in accordance with an embodiment of the invention. As noted earlier, heat spreader  32  comprises a continuous sheet of a heat-conducting material, which is folded to define a lower side  60  and an upper side  62 , connected by a lateral side  64 . Thus, in the pictured embodiment, heat spreader  32  is folded into a U-shape, with an opening in upper side  62  to accommodate window  30 . Alternatively, the heat spreader may be folded into a different shape, for example extending only around one or more of the lateral surfaces of module  26  without covering the upper surface, or forming a sleeve that extends fully around the upper and lower surfaces and two (or more) lateral surfaces of module  26 . All such folded shapes of the heat spreader are considered to be within the scope of the present invention. 
     As noted earlier, heat spreader  32  advantageously comprises a thin, continuous sheet of graphite, with thickness typically between 10 and 100 μm, for example 25 μm thick. (Graphite is not isotropic and has very high in-plane thermal conductivity, typically ˜1000 W·m −1 ·K −1 , but much lower through-plane conductivity, typically ˜10 W·m −1 ·K −1 .) Alternatively or additionally, heat spreader may comprise a metal foil, such as a copper or aluminum foil, which may be laminated onto or otherwise integrated with the graphite sheet. The heat spreader sheet may be backed with a thermally-conductive adhesive, which bonds the heat spreader to module  26 . 
       FIGS. 5A and 5B  are schematic sectional views of electronic module  26 , taken along the line labeled V-V in  FIG. 1 . (These two views are identical, with the exception of arrows  68  and  70  shown in  FIG. 5B  to illustrated heat flow.) In  FIG. 5A , it can be seen more clearly that lateral side  64  of heat spreader  32  extends around the lateral surface of operational subunit  38 . Due to the thermal contact between lower side  60  of heat spreader  32  and heat sink  34 , along with the thermal contact between heat sink  34  and backplate  40 , most of the heat generated in operational subunit  38  is conducted through the heat spreader and heat sink to the backplate, as indicated by arrows  68  in  FIG. 5B . The remaining heat is conducted through lateral side  64  of heat spreader  32  to upper side  62 . At least a part of this remaining heat is dissipated from upper side  62  through cover  24  of device  20 , as indicated by arrows  70 . Arrows  68  and  70  thus illustrate the redundant thermal paths provided by heat spreader  32  for removal of excess heat from module  26 . 
     It will be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art.

Metadata:
Filing Date: 20190703
Publication Date: 20201229
Grant Date: 20201229
Priority Date: 20190703
Inventors: HUANG, LIDU
AL-OKAILY, ALAA
PRAGADA, ANURANJINI
MISCHKE, COLLEEN F
IREDALE, DEREK J
MONSON, MICHAEL R
KALYANASUNDARAM, NAGARAJAN
CHEN, PENG
SOULOUMIAC, PIERRE P
Assignee: APPLE INC
CPC Classifications: [{"code": "H04N23/52", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04N23/57", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B17/55", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B30/00", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0264", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K7/2039", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/026", "inventive": true, "first": true, "tree": "[]"}, {"code": "G06F1/203", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/0264", "inventive": false, "first": false, "tree": "[]"}, {"code": "H05K7/20454", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K7/20509", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K7/20418", "inventive": true, "first": false, "tree": "[]"}, {"code": "H04M1/026", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B17/55", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B15/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "H04M1/026", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K7/20418", "inventive": true, "first": false, "tree": "[]"}, {"code": "G03B15/03", "inventive": false, "first": false, "tree": "[]"}, {"code": "G03B17/55", "inventive": true, "first": false, "tree": "[]"}, {"code": "H05K7/20509", "inventive": true, "first": true, "tree": "[]"}, {"code": "H05K7/20454", "inventive": true, "first": false, "tree": "[]"}]
Family ID: 73919543