Cooling-assisted, heat-generating electrical component and method of manufacturing same

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is related to U.S. application Ser. No. ______(Docket 84843), filed ______, by Tina P. Barcley, and entitled, “Insitu-Cooled Electrical Assemblage And Method Of Manufacturing Same;” and U.S. application Ser. No. ______(Docket 84844), filed ______, by Tina P. Barcley, and entitled, “Method of Cooling Heat-Generating Electrical Components.”

FIELD OF THE INVENTION

The invention relates to improvements in heat transfer in electronic technology. More particularly, the invention concerns electrical assemblages, such as circuit boards, which reduce heat generated in ceramic “chip” components during service.

BACKGROUND OF THE INVENTION

It is well known that overheating of electrical components, for instance components mounted on a circuit board, contributes to reducing the life of the component. Overall component reliability is also compromised by excessive overheating during service. As circuit boards become denser and contain components that have higher power output capacity, reliability problems become magnified for solder joints of the circuit board, particularly in “chip” ceramic type parts due to CTE (Coefficient of Thermal Expansion) differences.

The current trend in the industry is to either assume the reliability risk or to institute extremely expensive chip construction processes for removing excess heat. Both practices have proven undesirable from a cost management standpoint.

In a typical electronic package, the largest chip ceramic component, for instance the 2512 resistor, is the least reliable component on most circuit boards and the component most likely to fracture its solder joint due to thermal cycling. The thermal cycling occurs every time the component is used. It would, therefore, be desirable to cool this component during service to dramatically improve its useful life and reliability.

Therefore, a need persists in the art for a system and method of cooling electrical components, such as those mounted in circuit boards, during service that produces a component that is reliable, cost effective and has an extended useful life.

SUMMARY OF THE INVENTION

It is, therefore, an object of the present invention to provide an electrical component protected from deterioration due to overheating during service.

Another object of the invention is to provide such an electrical component that is considerably more reliable, has a longer useful life and is cost effective to build and use.

The present invention is directed to overcoming one or more of the problems set forth above. Briefly summarized, according to one aspect of the present invention, an electrical component has a heat-generating main portion having a junction temperature T_j and at least one mating surface. Means for reducing the junction temperature T_j of the heat-generating main portion has at least one heat-removing element. The heat-removing element comprises a plurality of arranged thermal vias and is electrically associated with the mating surface to form a thermal transport path for heat flow away from said heat-generating main portion.

In another aspect of the invention, a method of manufacturing a cooling assisted, heat-generating electrical component, comprising the steps of providing a heat-generating electrical component having at least one mating portion. A heat-removing element is affixed to the mating portion of the heat-generating electrical component such that heat removed therefrom follows a path from the heat-generating electrical component through the heat-removing element.

The present invention has numerous advantages over existing developments including reliability, cost effectiveness, ease of development, and increased component useful life. Moreover, the present invention has the advantage of being applicable to practically any ceramic chip, ball grid array (BGA), direct die attached components, chip-on-board, and smaller chip resistors, such as the 2010, 1206, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other objects, features, and advantages of the present invention will become more apparent when taken in conjunction with the following description and drawings wherein identical reference numerals have been used, where possible, to designate identical features that are common to the figures, and wherein:

FIG. 1 is an elevated plan view of an electrical component having the heat-removing element of the invention;

FIG. 2 is an elevated front plan view of an electrical component having alternative heat-removing elements thereon;

FIG. 3 is a cross-sectional view of a typical circuit board construction having the heat-removing element of the invention thereon; and,

FIG. 4 is a plan view of a solder stencil used for automated manufacturing of heat-removing element and thermal vias.

DETAILED DESCRIPTION OF THE INVENTION

Turning now to the drawings, and in particular to FIGS. 1 and 2, the electrical component 10 of the invention is illustrated. According to FIG. 1, electrical component 10, for instance a resistor or capacitor, has mating portions 12, 14 and a heat-removing element 16 attached to either of mating portions 12, 14. Electrical component 10 is preferably made of a ceramic or ceramic-like material for suitability of die usage or affixing other electrical components (multi-chip module). Although soldering is the preferred method of attaching heat-removing element 16 to either of mating portions 12, 14, skilled artisans will appreciate that other methods may be used including using electrically conductive adhesives. Mating portions 12, 14 are typically gold or palladium tipped for best thermal conductivity and solderability. Skilled artisans will appreciate that, alternatively, the mating portions 12, 14 may comprise other thermally conductive materials such as tin-lead.

According to FIG. 1, heat-removing element 16 has a plurality of thermal vias 18 that provides the mechanism for effectively removing heat from the electrical component 10. The thermal conductivity of thermal vias 18 is enhanced as possible with the addition of solder or some thermal compound either partially or totally filling the inner walls (not shown) of thermal vias 18. Thermal vias 18 may have practically any size diameter. A preferred range for the diameter is about 0.022 inches to about 0.040 inches. However, a diameter in the range of about 0.022 inches to about 0.028 inches is more preferred.

As shown in FIG. 3, skilled artisans will appreciate that thermal vias 18 may be electrically connected to a high density copper plane 20 to increase the thermal conductivity of the vias 18. Therefore, practically any high density copper circuit or collection of signals can be used to increase the thermal conductivity of the vias 18. The maximum effect on thermal conductivity is realized when the thermal vias 18 are connected to a large copper area, such as high-density copper plane 20. Typically, large copper areas are generally used for grounds and power circuits. This construction would also include a bonded heat sink 40, as described below. Use of a thermal conductive bonding adhesive or thermally conductive compound will effectively maximize the heat transfer to the heat sink.

Referring to FIG. 3, an electrical assemblage 30 is illustrated. According to FIG. 3, electrical assemblage 30 includes a main portion, or circuit board 32, and at least one heat-generating component 34, each with the heat-removing elements 16 of the invention. Heat-removing element 16, as described above, has a plurality of thermal vias 18 for transporting heat away from heat-generating component 34. Heat-generating component 34 has a junction temperature T_j. To reduce the junction temperature T_j of the heat-generating component 34, the thermal vias 18 transport the heat generated by component 34 to the bottom outer layer 38 of circuit board 32. The heat is then transported from the bottom outer layer 38 to the adjoining heat sink 40. Heat sink 40 may be adjoined to bottom outer layer 38 with, for instance, a thermally conductive adhesive material. In this way, the junction temperature T_j of the heat-generating component 34 is reduced to a temperature T₁, wherein T₁ is less than T_j.

As an example, a 10-layer polyimide circuit board 32 may comprise ½ oz. copper on the inner layers 35 and 1 oz. copper on the outer layers 37 (top), 38 (bottom). The heat-removing element 16 of the invention can be used with any material circuit board since the primary heat transfer mechanism is conduction through the thermal vias 18. Moreover, heat-removing element 16 can be used on any number of layers or copper weight available from any circuit board manufacturer. Current industry standards for circuit board plating include Pd, NiAu, Immersion Tin, Immersion Ag, and HASL for plating types. The specific board material was polyimide, but any board material where vias can be drilled could use this invention (FR2, FR4, CEM, Rogers, etc.). For the electrical assemblage 30 of the invention, a particular pattern of thermal vias 18 is used on the heat-removing element 16. The thermal vias 18 are preferably about 0.025 inches in diameter with a grid spacing of about 0.040 inches center-to-center for the hole pattern (see for instance, FIGS. 1 and 2). This hole pattern provides a specific cross-sectional area of copper in the circumference of the thermal vias 18 to conduct the heat from the top outer layer 37 of the circuit board 32 to the bottom outer layer 38. The copper of heat-removing element 16 is used to transport heat across the surface of the circuit board 32. Additionally, the similar heat-removing elements on the bottom outer layer 38 of the circuit board 32 enhance the transport of the heat from the thermal vias 18 to the heat sink 40.

Referring again to FIGS. 1 and 2, heat-removing element 16 may have practically any geometric configuration. In FIG. 1, heat-removing element 16 is substantially rectangular shaped. As shown in FIG. 2, alternatively, heat-removing element 16 may be substantially T-shaped. In this latter design the T-shaped pads are used to separate the thermal vias 18 from mating surfaces 12, 14 to improve solderability and manufacturability. Typically one would stay away from the actual solder joint (not shown), i.e., the interface of the mating surface 12, 14 and the heat-removing element 16 of the electrical component 10 in order to maintain solder joint integrity. Separation of thermal vias 18 from the mating surfaces 12, 14 may be accomplished by use of webs 22, typically comprising copper, on circuit board 32. Any number of webs 22 may be used depending on the application.

Referring to FIG. 3, electrical assemblage 30 of the invention has an aluminum heat sink 40 that is 0.090 inches thick. The heat sink 40 was attached via adhesive layer 39 to the circuit board 32 using an Arlon Thermobond® silicone, thermally conductive, electrically isolative adhesive film. Any metal heat sink 40 could have been used of any thickness, preferably between 0.060 inches and 0.090 inches. Additionally, any thermally conductive compound or adhesive (including epoxies and liquid silicones) could be used with substantially similar results. Those skilled in the art will appreciate that thermally conductive, electrically conductive adhesives may be used as a substitute for thermally conductive compounds.

Turning now to FIG. 4, to construct electrical assemblage 30 of the invention, a solder stencil 50 may be used to automatically apply solder paste to the circuit board 32 in high volume electronic applications. Solder stencil 50 has at least one cut-out portion 52 (two are shown) which provides a path for the solder paste to be applied to the heat-removing elements 16 of circuit board 32. Although this process may be accomplished manually, solder stenciling has the advantage of consistency and ease of use. The solder stencil 50 has standard support features that reduces sagging in the vicinity of the cut-out portions 52. The amount of solder paste applied to the heat-removing elements 16 can be increased by increasing the size of the cut-out portions 52. The increased amount of solder paste associated with the increased sizes of the cut-out portions 52 will accommodate the volume of paste that eventually fills the thermal vias 18.

The invention has been described with reference to a preferred embodiment. However, it will be appreciated that variations and modifications can be effected by a person of ordinary skill in the art without departing from the scope of the invention.

PARTS LIST

• 10 electrical component
• 12, 14 mating portion of 10
• 16 heat-removing element
• 18 thermal vias
• 20 high density copper plane
• 22 webs of heat-removing element 16
• 30 electrical assemblage
• 32 circuit board
• 34 heat-generating component
• 35 inner layers of circuit board 32
• 37 top outer layer of circuit board 32
• 38 bottom outer layer of circuit board 32
• 39 adhesive layer
• 40 heat sink
• 50 solder stencil
• 52 cut-out portion of solder stencil 50