1. R&D of module and service structure -Super module concept - Takashi Kohriki

2. 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.

3. Super module concept Fabricate and test individual modules Thin module - front-back correlation Basic concept is to mount the modules on to cylinder Overlapping geometry without sensitive gap Module replaceability is critical Make a row of modules into a unit with super-frame Unit is testable with cooling loops included Cooling might be required in both 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)

4. Module (4 Hybrid-connectors)

5. Module (2 Hybrid-connectors)

6. Hybrid-Service connection Mass 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)

7. SuperModule - detail

8. SuperFrame

9. SuperModule

10. End view at Z=0

11. End view at end

12. Bracket on cylinder

13. SuperModule on cylinder

14. SuperModule installation

15. Next step Calculation/estimation of the diameter of the cooling 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 mechanical and thermal measurements –Optimization of 3rd mounting points