Claims
- 1. A variable-gap thermal-interface device for transferring heat from a heat source to a heat sink, said device comprising:
a multi-axis rotary spherical joint comprising a spherically concave surface having a first radius of curvature in slideable contact with a spherically convex surface having said first radius of curvature; a block having a proximal end rotatably coupled with said heat sink through said rotary spherical joint and having a distal end opposite said proximal end; and a wedge having a variable thickness separating a first surface and a second surface, said second surface opposite and inclined relative to said first surface, said first surface thermally coupled with said distal end of said block and said second surface thermally coupled with said heat source.
- 2. The device of claim 1 wherein said spherically concave surface is integral with said block.
- 3. The device of claim 1 wherein said spherically convex surface is integral with said block.
- 4. The device of claim 1 wherein said multi-axis rotary spherical joint is rotated to an orientation that compensates for angular misalignment between said heat source and said heat sink.
- 5. The device of claim 1 wherein said wedge is operable to be variably offset relative to an axis connecting said distal end with said proximal end of said block.
- 6. The device of claim 5 wherein said wedge is operable to fill a variable-gap between said block and said heat source in response to said variable offset.
- 7. The device of claim 5 further comprising a spring clip mechanically coupled to said wedge, said spring clip operable to apply a shear force between said block and said wedge.
- 8. The device of claim 7 wherein said spring clip is shaped approximating a deformed rectangular frame, comprising:
a first side and a second side opposite said first side, wherein said first and second sides are bent inward toward one another; said first side operable to couple a compressive force to said wedge; and said second side operable to couple a compressive force to said block.
- 9. The device of claim 1 further comprising a thermal-interface material applied to interfaces within said multi-axis rotary spherical joint and to interfaces adjacent said inclined surfaces of said wedge.
- 10. The device of claim 1 further comprising a heat sink extension thermally and mechanically coupled between said heat sink and said multi-axis rotary spherical joint.
- 11. The device of claim 1 wherein said block, said wedge, and said multi-axis rotary spherical joint consist substantially of high thermal conductivity solid materials.
- 12. The device of claim 11 wherein said solid high thermal conductivity materials are selected from the group consisting of metals, insulators, semiconductors, and composite materials.
- 13. The device of claim 12 operable to transfer heat from said heat source through said wedge, through said block from said distal end to said proximal end, and through said rotary spherical joint to said heat sink.
- 14. The device of claim 13 further operable to transfer heat under compressive loading applied between said heat sink and said heat source.
- 15. The device of claim 14 coupled mechanically and thermally with a heat sink hold-down device, wherein said heat sink hold-down device is operable to apply said compressive loading.
- 16. The device of claim 1 wherein said heat source comprises an integrated circuit chip.
- 17. A spring clip shaped approximating a deformed rectangular frame, said spring clip comprising:
a first side and a second side opposite said first side, wherein said first and second sides are bent inward toward one another; and said spring clip operable to couple a shear force between components of a wedge interface.
- 18. The spring clip of claim 17 mechanically coupled to said wedge interface, comprising:
said first side operable to couple a compressive force to a wedge component; and said second side operable to couple a compressive force to a block component slideably contacting said wedge component.
- 19. A method of transferring heat from a heat source to a heat sink using a variable-gap thermal-interface device, said method comprising:
providing a multi-axis rotary spherical joint; rotating said multi-axis rotary spherical joint to an orientation to compensate for misalignment between said heat source and said heat sink; providing a wedge having a variable thickness separating a first surface and a second surface opposite and inclined relative to said first surface, said second surface thermally coupled with said heat source; and offsetting said wedge sufficiently to fill a gap between said heat source and said multi-axis rotary spherical joint.
- 20. The method of claim 19 further comprising:
providing a spring clip mechanically coupled to said wedge; and applying a shear force causing said offset of said wedge.
- 21. The method of claim 19 further comprising applying thermal-interface material to interfaces within said multi-axis rotary spherical joint and to said inclined surfaces of said wedge.
- 22. The method of claim 19 further comprising transferring heat from said heat source through said wedge and through said multi-axis rotary spherical joint to said heat sink.
- 23. The method of claim 19 further comprising applying a compressive load between said heat sink and said heat source.
- 24. The method of claim 23 wherein said applying a compressive load further comprises:
providing a heat sink hold-down device operable to apply a compressive load; coupling said heat sink, said multi-axis rotary spherical joint, said wedge, and said heat source mechanically and thermally with said heat sink hold-down device; and applying a compressive load between said heat sink and said heat source using said heat sink hold-down device.
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is related to concurrently filed, co-pending, and commonly assigned U.S. Patent Application [Attorney docket 200206899-1], titled “HEAT SINK HOLD-DOWN WITH FAN-MODULE ATTACH LOCATION,” and to concurrently filed, co-pending, and commonly assigned U.S. Patent Application [Attorney docket 200207213-1], titled “VARIABLE-GAP THERMAL-INTERFACE DEVICE,” the disclosures of which are hereby incorporated herein by reference. This application is further related to co-pending and commonly assigned U.S. patent application Ser. No. 10/074,642, titled THERMAL TRANSFER INTERFACE SYSTEM AND METHODS,” filed Feb. 12, 2002, the disclosure of which is hereby incorporated herein by reference.