Embedded-lattice-jig, isothermal, truss-plate apparatus and method

Abstract

Modular thermal truss plates are structures to hold mechanical loads of devices while also distributing heat in multiple directions “in plane” parallel to the truss plate, and “through-plane” orthogonal to the planar direction. An embedded lattice forms spaces or slots to receive thermally conductive spacer inserts conducting “through-plane” (a comparatively short distance, in a plate thickness direction) as well as comparatively longer (than the comparatively short distance) relief “channels” extending across from edge to edge (in the planar directions) sized for receiving flat heat pipe strips transferring heat therealong. With precision available by pre-fabricating the lattice with pre-threaded holes at vertices, the assembly into it of heat pipes and conductive inserts as well as attachment of outer skins and framing is faster, more precise, and reliable, with no need for risky or imprecise measuring or drilling after assembly.

1 . An apparatus operable as a lightweight, isothermal, structural mounting plate, the apparatus comprising:
 a lattice, defining first and second faces each defining a plane constituted by two dimensions, formed of polygons, the polygons being defined by walls extending between vertices of the polygons and extending in a “through-plane” direction defining a lattice thickness between the first and second faces, the lattice containing pillars at selected ones of the vertices provided with pre-threaded holes extending therinto in a through-plane direction;   a first plurality of flat heat pipes recessed into the first face to extend in a first planar direction, and a second plurality of flat heat pipes recessed into the second face to extend in a second planar direction orthogonal to the first planar direction;   inserts, thermally conductive in the through-plane direction, lightweight in cross-section in the planar direction, and fitted into the polygons;   outer skins registered to cover the lattice, inserts, and flat heat pipes by aligning mounting holes therein with the pre-threaded holes in the pillars; and   bonding material applied to increase thermal conductivity and mechanical strength between the first and second plurality of flat heat pipes and the outer skins.   
     
     
         2 . The apparatus of  claim 1 , comprising the bonding material applied between the first and second pluralities and the lattice, and between the first and second pluralities. 
     
     
         3 . The apparatus of  claim 1 , comprising the bonding material applied between the lattice and the outer skins. 
     
     
         4 . The apparatus of  claim 1 , comprising the bonding material applied between the inserts and flat heat pipes and between the inserts and the outer skins. 
     
     
         5 . The apparatus of  claim 1 , wherein the inserts have a honeycomb cross section “in plane.” 
     
     
         6 . The apparatus of  claim 1 , wherein the lattice is provided with relief channels sized to receive the flat heat pipes in the first and second faces, the relief channels constituted by selected ones of the walls that do not reach completely across the lattice thickness. 
     
     
         7 . The apparatus of  claim 1 , wherein the lattice is fabricated as a single, continuous, monolithic piece by one of machining and casting. 
     
     
         8 . The apparatus of  claim 1 , comprising pins capable of registering the outer skins with the lattice and the pre-threaded holes by being selectively securable and removable from the pre-threaded holes in the pillars. 
     
     
         9 . The apparatus of  claim 1 , comprising:
 a frame comprising rails surrounding the outer skins; and   peripheral inserts fitted between the outer skins, the lattice, and the frame.   
     
     
         10 . The apparatus of  claim 1 , comprising:
 bonding material securing the first and second pluralities of flat heat pipes, each one of the flat heat pipes having a length greater than a width thereof and a width greater than a thickness thereof, into a relief channel recessing into the corresponding first or second face of the lattice;   the inserts fit into corresponding ones of the polygons to fill the entire thickness of the lattice with at least one of insert material, flat heat pipe material, bonding material, and a combination thereof; and   the outer skins are registered directly with the lattice by the pre-threaded holes in the pillars, and bonded to the first and second faces of the lattice.   
     
     
         11 . A method comprising:
 providing a lattice, generally planar in configuration defining first and second lattice faces and a lattice thickness extending and defined directly therebetwen, the lattice comprising walls extending in the thickness direction orthogonally to the planar direction as well as extending and connecting at vertices “in plane” to define spaces therebetween, the lattice being capable of operating as an embedded jig for assembling a thermomechanical panel capable of structural support and heat distribution for devices secured to the thermomechanical panel;   providing first and second pluralities of heat pipes as strips, each individual heat pipe thereof having a strip length multiple times a strip width, and a strip width multiple times a strip thickness;   providing a plurality of inserts, each insert extending as a collection of interconnected solid walls in the lattice thickness direction and having a matrix of polygons as a cross-section “in plane”;   placing each heat pipe of the first plurality into a corresponding relief region proximate the first lattice face and within the lattice thickness, each heat pipe spanning multiple spaces and crossing multiple legs;   placing each heat pipe of the second plurality into a corresponding relief region proximate the second lattice face and within the lattice thickness, each heat pipe of the second plurality spanning multiple spaces and crossing multiple legs;   placing each insert into one of the spaces; and   bonding an outer skin to each of the lattice faces.   
     
     
         12 . The method of  claim 11 , comprising applying a bonding material between the walls and a corresponding outer skin. 
     
     
         13 . The method of  claim 11 , comprising applying a bonding material between each heat pipe and the lattice. 
     
     
         14 . The method of  claim 13 , comprising bonding the first plurality of heat pipes to the second plurality of heat pipes at intersections thereof. 
     
     
         15 . The method of  claim 11 , wherein the strip lengths are all equal. 
     
     
         16 . The method of  claim 11 , wherein each of the inserts is individually positionable in at least one of the faces of the lattice after securement of all the strips into the relief regions of the lattice. 
     
     
         17 . The method of  claim 11 , comprising bonding a first outer skin to selected ones of the strips and of the inserts at one face of the lattice and bonding a second outer skin to other ones of the strips and of the insert at a second face of the lattice. 
     
     
         18 . A method for assembling a lightweight, isothermal, structural mounting plate, the method comprising:
 fabricating a lattice, having first and second faces, of polygons, defining a planar, that is, “parallel to a plane,” direction in two dimensions, the polygons defined by walls extending between vertices of the polygons and extending in a “through-plane” direction a lattice thickness, at right angles to the planar direction, the lattice containing pillars at certain vertices provided with pre-threaded holes extending in the through-plane direction;   providing inserts, thermally conductive in the through-plane direction and fitted to the polygons, flat heat pipes, and bonding material;   bonding a first plurality strips, each constituting one of the flat heat pipes having a length greater than a width thereof and a width greater than a thickness thereof, into the first face of the lattice;   bonding a second plurality of strips, each constituting another flat heat pipe into the second face of the lattice, opposite the first face to extend lengthwise orthogonal to the first plurality; and   positioning inserts into corresponding ones of the polygons to fill the entire thickness of the lattice with at least one of insert material, flat heat pipe material, bonding material, and a combination thereof.   
     
     
         19 . The method of  claim 18 , comprising:
 providing outer skins capable of covering the lattice and provided with through-holes corresponding to the pre-threaded holes in the pillars; and   bonding the outer skins to the first and second faces of the lattice.   
     
     
         20 . The method of  claim 19 , comprising:
 registering the outer skins using pins to align the pre-threaded holes with the through-holes in the outer skins; and   mounting devices to be mechanically supported by and thermally conductive to at least one of the outer skins by fasteners threaded into the pre-threaded holes.