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

Abstract

A cooling-assisted, heat-generating electrical component reduces heat generated during operation. The electrical component, typically a resistor, has a least one heat-removing element electrically associated therewith. Heat-removing element comprises a plurality of thermal vias therein and is fixedly attached to an end portion of the electrical component, typically on opposed end portions. Heat absorbed by the heat-removing element can be transported away from the electrical component during service.

1 . A cooling-assisted electrical component, comprising: 
 a heat-generating main portion having a top surface a bottom surface, a junction temperature T j  and at least one mating surface; and,    means for reducing said junction temperature T j  of said heat-generating main portion comprising at least one two-piece heat-removing element having a top pad on said top surface, a bottom pad on said bottom surface and a plurality of thermal vias therein extending between said top and bottom pads, said at least one heat-removing element being electrically associated with said at least one mating surface to form a thermal transport path for heat flow away from said heat-generating main portion through said top pad, thermal vias and bottom pad.    
   
   
       2 . The electrical component recited in  claim 1  wherein said plurality of thermal vias are arranged in a grid-like pattern with each one of said plurality of thermal vias having a diameter of about 0.025 inches.  
   
   
       3 . The electrical component recited in  claim 2 , wherein nearest adjacent thermal vias are spaced about 0.040 inches apart as measured from a center portion of a first thermal vias to a second center portion of a nearest adjacent second thermal vias.  
   
   
       4 . The electrical component recited in  claim 2  wherein each one of said plurality of thermal vias is filled with a thermally conductive compound.  
   
   
       5 . The electrical component recited in  claim 2  wherein each one of said plurality of thermal vias is filled with a solder material.  
   
   
       6 . The electrical component recited in  claim 2  wherein said at least one heat-removing element is affixed to a gold tipped portion of said at least one mating portion.  
   
   
       7 . The electrical component recited in  claim 2  wherein said at least one heat-removing element is affixed to a palladium tipped portion of said at least one mating portion.  
   
   
       8 . The electrical component recited in  claim 2  wherein said at least one heat-removing element is affixed to a tin-lead tipped portion of said at least one mating portion.  
   
   
       9 . A method of manufacturing a cooling assisted, heat-generating electrical component, comprising the steps of: 
 providing a heat-generating electrical component having a top surface, a bottom surface and at least one mating portion and;    affixing a two-piece heat-removing element having a top pad and a bottom pad connected by a plurality of thermal vias to said at least one mating portion of said heat-generating electrical component such that said top pad is on said top surface and said bottom pad is on said bottom surface so that heat removed therefrom follows a path from said heat-generating electrical component through said top pad, thermal vias and bottom pad of said heat-removing element.    
   
   
       10 . The method recited in  claim 9  further comprising the step of affixing a heat sink in fluid communications with said bottom pad of said heat-removing element to transport heat from said path and away from said heat-removing element.  
   
   
       11 . The method recited in  claim 9  wherein said step of providing a heat-generating component comprises the step of providing mating portions on opposing end portions of said heat-generating component and then affixing a heat-removing element to each of said end portions.  
   
   
       12 . The method recited in  claim 11  further comprising the step of affixing a heat sink to said heat-removing element on each of said end portions.