R&D of module and service structure

-Super module concept -

Takashi Kohriki

Content• Concept• Module(4 Hybrid-connectors)• Module (2 Hybrid-connectors)• Hybrid-Service connection• SuperModule - detail• SuperFrame• SuperModule

• End view at Z=0• End view at end• Bracket on cylinder• SuperModule on cylinder• SuperModule installation• Next step

Drawings are made with 9-chips modules for availability of CAD drawing components.

Super module concept• Fabricate and test individual mo

dules• Thin module - front-back correla

tion• Basic concept is to mount the m

odules on to cylinder• Overlapping geometry without s

ensitive gap• Module replaceability is critical• Make a row of modules into a u

nit with super-frame• Unit is testable with cooling loop

s included• Cooling might be required in bot

h sides as the heat density is 4 times higher

• Make the thermal contact of the modules and the cooling plates better

• Make the cooling pipe to slide so that the move of the pipe should not be transmitted to the module

• Mass of the super-frame could be compensated with– elimination of dog-legs of

the service harness

– reduction the number of brackets - slender and one per two modules

– Carbon-carbon cooling blocks instead of Al blocks

– length of the cooling pipe is twice, but compensated with smaller diameter and no solder (of the cooling block)

Module (4 Hybrid-connectors)

Module (2 Hybrid-connectors)

Hybrid-Service connectionMass reduction in the connection(1)Not to use a connector,two methods: (a)direct soldering,no Al conductor (b)wire-bonding,thick wire,with reinforcement(2)Use a miniature connector,three methods: (a)ZIF FPC-connector (b)Low-profile PCB-PCB connector(a la PIXEL) (c) Low-profile PCB-PCB connector(a la SCT)Note:all are similar once a reinforcement piece is included(3)Reduce the number of connectors (a)4 connectors/module(2 connectors x2 sides) (b)2 connectors/module(1 connectors x2 sides)

SuperModule - detail

SuperFrame

SuperModule

End view at Z=0

End view at end

Bracket on cylinder

SuperModule on cylinder

SuperModule installation

Next step• Calculation/estimation of the diameter of the c

ooling pipe• Thermal and Mechanical FEA calculation• Design of the service cables/harness

– Number of traces, including DCS

• Investigation of the connectors in industry• Minimization of parts• Tabulation of materials, comparison• Design of the hybrids• Manufacturing of the super-frame model for m

echanical and thermal measurements– Optimization of 3rd mounting points