onecoolirishlad wrote:
+"Also, the thermal interfaces between those chips and the heat spreader/heat pipe assembly can't be that good -- it is hard to make something that large with that many different mechanical interfaces flat enough to have a thin thermal interface. That must be why the Apple Service Manual for the MBP requires such a huge amount of thermal interface material to be used. Filling in the big (relatively) gaps that are probably present in one or more of those interfaces takes a lot of goo."+
I'm not sure exactly what you mean here with the difficulty of making an efficient heat sink system.
Normally heat sink systems are not hard to design or manufacture, but this one is different from most heat sink systems found in computers because the one in the MacBook Pro is a single, apparently rigid, piece that is meant to contact all three dies simultaneously. Normal CPU heat sink systems, for instance, have a single flat surface that contacts a single die and something surrounding the interface that puts a known and approximately constant amount of force on the interface. The single thermal interface in such a system means that only one mechanical datum is functionally significant in determining the thicknes of the interface -- the die itself. In the MacBook Pro system, there are three mechanical data to which the heat sink must be aligned, and these are all in nominally fixed positions relative to each other. (Of course the PCB can flex a bit, and the heat sink in this case may be able to flex a significant amount as well.) Considering that the three BGA packages are soldered to the logic board, and that their positions relative to each other are essentially finalized when the solder cools, if someone were to try to guarantee a thermal interface thickness similar to a single interface solution, they would need to control the tolerances of the positions of the heat sink surfaces relative to each other and the tolerances of the IC dies relative to each other such that the manufacturing of the heat sink assembly and the population of the logic board with the BGA packages would probably require non-standard techniques. I suspect that they thought they had shown a "good enough" interface thickness, and therefore, "good enough" cooling, using the method that ended up being used in our laptops. Perhaps they didn't expect that high die temperatures would cause errors as quickly as they have.
I also want to clear up some misconceptions of the heat sink/thermal grease issue that others may have. The TG is supposed to be applied conservatively due to the fact that the thermal resistance is directly proportional to the thickness of applied grease. It's main purpose is not to solely transfer heat from the die to copper; it's supposed to turn an imperfectly flat surface into a "perfect" one, i.e. fill the gaps. Copper does a mighty fine job of transferring heat internally, but it has a tendency to not exhibit the surface smoothness required to do so at the efficiency needed for a computer. Ergo, the assembly manual (assuming that what we've seen is the official manual) is wrong. AMD even states that the amount required shouldn't exceed a grain or two of rice. Ironically, Macs are assembled in China. (no offense)
I think that's what you said, so I'm probably just regurgitating. Also I found some data/evidence to back up these claims:
page 8 has good pictures showing the purpose of filling the gaps:
http://www.amd.com/us-en/assets/contenttype/white_papers_and_techdocs/26951.pdf
the relation between thermal resistance and thickness:
http://www.microsi.com/packaging/thermal_grease.htm
Right. Note that the examples in those documents assume a single interface heat sink situation, where the surface planes of the heat sink and the die will automatically settle nicely against each other when the proper amount of pressure is applied. That pressure-induced settling squeezes out excess thermal material, (although it takes time for that to happen,) and normally causes a thin, even thermal interface. As an additional bit of evidence in support of the "multiple interface heat sinks are a bad idea" theory, look at photos of the interface material left on the heat sink surfaces and the dies after the interface has been separated -- the interface is clearly thinner on one corner of the die than on the other corners most of the time. That suggests to me that the interface isn't very thin at all on average. Knowing that these surfaces weren't typically going to align as well as they would if they used 3 separate heat sinks, perhaps Apple tried to at least make sure there weren't any gaps in the interface by suggesting a big pile of grease be used on each one. If that is true, one wouldn't want to use a normal amount of thermal grease, because even if it isn't necessary to use a larger amount, a larger amount would insure that in the worst alignment case, there aren't any corners of the die that don't even have a wad of thermal grease serving as a heat spreader.