Insulation mat for the power electronics of a motor vehicle

Abstract

The invention relates to an insulation mat for the power electronics of a motor vehicle, comprising at least the following components: - an electrically and thermally insulating carrier film, and - Electrically insulating and thermally conductive filling material. The insulating mat is characterized primarily by the fact that the carrier film has at least one guide recess by means of which the carrier film can be aligned during installation. An insulation mat with guide recesses in the carrier film is proposed, which simplifies assembly.

Description

[0001] The invention relates to an insulating mat for power electronics of a motor vehicle, a pre-assembly unit with such an insulating mat for power electronics of a motor vehicle, power electronics with such a pre-assembly unit for a motor vehicle, and a manufacturing method for power electronics.

[0002] Power electronics for battery-electric or hybrid vehicles are known from industrial practice, enabling the control of the vehicle's high-voltage electrical system. Such power electronics include, for example, a battery junction box and a current control unit. The battery junction box contains components such as fuses, contactors, and busbars or conductors to the individual components of the high-voltage system. The current control unit includes components such as power converters, for example, AC-DC converters or DC-DC converters.

[0003] The electrical power losses of both the battery junction box components and the power control unit components must be dissipated by means of cooling. Solutions are known from industrial practice where a common cooling plate, which is integrated into the power control unit, is used for both the power control unit and the battery junction box. The high-voltage components of the battery junction box that require cooling are thermally coupled to the cooling plate by means of a thermally conductive filler material, also known as a gap pad or gap filler. The filler material is, for example, bonded to the cooling plate using a carrier film.

[0004] The disadvantage is that the filling material is difficult to install.

[0005] DE 102 37 716 A1 discloses an electronic unit with a thermally conductive distribution element, in which a thermally conductive film is arranged between an electronic assembly and a housing and is pressed in a defined manner in the area of ​​a through-opening via a connecting element with a clamping ring and axial stop, thereby achieving a reproducible contact pressure and a reliable thermal contact without over-compression of the film; the film can be multi-layered and / or segmented and have cutouts for feedthroughs.

[0006] DE 20 2024 102 566 U1 discloses a Gappad, a Gappad device and an electronic system, wherein the Gappad comprises an elastic, compressible core element and a conductive, preferably graphitic, sheathing that covers the core element on at least two side surfaces as well as on the top and bottom surfaces, so that heat dissipation from the top to the bottom surface is possible; at least one tab projecting laterally beyond an end face is provided for fixing to a heat sink and is held clamped in the Gappad device between a frame element and the heat sink, wherein an internal self-adhesive layer is optionally provided for positioning on the frame element and several Gappads can be arranged side by side and clamped together.

[0007] DE 10 2023 200 062 A1 discloses a busbar arrangement for cooling a busbar with a layered structure consisting of a busbar, a first thermally conductive material, an insulating film, a second thermally conductive material and a cooling medium, wherein the insulating film protrudes on both sides in the second horizontal direction relative to the thermally conductive materials and the protrusion is bonded to a housing to prevent creepage paths; the connection between the insulating film and the housing can be made by ultrasonic welding, laser welding, injection molding (film insert molding) or bonding, the housing can be made of plastic (optionally fiber-reinforced), and the cooling medium can be made of metal, in particular aluminum or copper, and provide efficient heat dissipation.

[0008] Based on this, the present invention aims to overcome, at least partially, the disadvantages known from the prior art. The features of the invention are defined in the independent claims, for which advantageous embodiments are shown in the dependent claims. The features of the claims can be combined in any technically meaningful way, whereby the explanations in the following description and features from the figures, which comprise supplementary embodiments of the invention, can also be used.

[0009] The invention relates to an insulation mat for the power electronics of a motor vehicle, comprising at least the following components: - an electrically and thermally insulating carrier film; and - Electrically insulating and thermally conductive filling material.

[0010] The insulation mat is characterized primarily by the fact that the carrier film has at least one guide recess, by means of which the carrier film can be aligned during installation.

[0011] Unless explicitly stated otherwise, ordinal numbers used in the preceding and following descriptions serve solely for unambiguous differentiation and do not indicate any order or ranking of the components referred to. An ordinal number greater than one does not necessarily imply the presence of another such component.

[0012] An insulating mat for the power electronics of a motor vehicle, preferably an electric or hybrid vehicle, is proposed here. The power electronics are designed to regulate the vehicle's high-voltage electrical system.

[0013] The insulation mat has an electrically and thermally insulating carrier film and an electrically insulating and thermally conductive filling material.

[0014] The insulation mat has a principal plane extending transversely, preferably orthogonally, to an insulation direction. Preferably, the thickness of the insulation mat along the insulation direction is greater, preferably many times greater, than the width and length of the insulation mat arranged in the principal plane.

[0015] The carrier film is electrically and thermally insulating. Electrically insulating in this context means that the material has a high electrical resistance, high dielectric strength, and / or low electrical conductivity. The electrical resistance is preferably at least one megaohm, and particularly preferably at least ten megaohms. The electrical conductivity is preferably a maximum of 10 -10S / m [Siemens per meter], particularly preferably a maximum of 10 -12 S / m [Siemens per meter]. Preferably, the dielectric strength is at least 10 kV / mm [ten kilovolts per millimeter].

[0016] Preferably, the carrier film comprises a plastic. For example, the carrier film comprises at least one of the materials from the following list: - Polyimide [PI]; - Polyethylene [PE]; - Polyethylene naphthalate [PEN]; - Polyethylene terephthalate [PET]; - Polyvinyl chloride [PVC]; - Polypropylene [PP]; and - Fluoropolymers [e.g. PTFE, FEP].

[0017] The backing film supports the filling material, also known as gap pad or gap filler. Preferably, the backing film is designed to simplify handling the insulation mat, for example, during installation. For instance, the backing film is designed to mechanically stabilize the insulation mat.

[0018] The electrically insulating and thermally conductive filler material, also known as gap pad or gap filler, is designed to provide a thermal interface and electrical insulation between a current-carrying component and a heat sink. The insulating mat is positioned along the insulation direction between the heat sink and the current-carrying component. The filler material is designed to maximize thermal conductivity between heat-generating, current-carrying components and heat sinks to ensure efficient heat dissipation, while simultaneously providing electrical insulation to prevent short circuits and electrical breakdowns.

[0019] The filling material exhibits high electrical insulating properties to prevent unwanted current flow, such as electrical short circuits and / or breakdowns. This is achieved through high dielectric strength and / or high electrical resistance, as defined above.

[0020] The filler material is thermally conductive to transfer heat from the heat-generating, current-carrying component, such as a high-voltage component (e.g., a busbar in the battery junction box), to a heat sink (e.g., a cooling plate). For example, the filler material has a thermal conductivity in the range of 1 W / mK to 10 W / mK [watts per meter and Kelvin].

[0021] For example, the filler material is designed to conform to the surfaces of the components to be coupled in order to ensure efficient thermal coupling. To this end, the filler material has, for example, a soft and compressible structure that allows it to bridge unevenness and surface roughness. Preferably, the filler material is also elastic, so that, for example, deformations and aging effects of the battery cells during operation can be compensated for. Alternatively or additionally, the filler material is, for example, adapted to the surface during application and then hardens. Preferably, the filler material hardens elastically, so that it remains elastic even after hardening, as described above.

[0022] For example, the filling material contains at least one of the materials from the following list: - Silicone; - Ceramic particles, which are embedded, for example, in a matrix of the filler material, for example, made of aluminum oxide [Al2O3] and / or boron nitride [BN]; and - Plastics and polymers, for example as matrix material.

[0023] It is proposed here that the carrier film has at least one guide recess to align the carrier film and thus the insulation mat during installation. Preferably, the carrier film has multiple, and particularly preferably two, guide recesses.

[0024] For example, the guide recess is a hole and / or an elongated slot. The guide recess is designed and arranged in such a way that, during installation of the insulation mat, the filling material comes into contact with the areas of the current-carrying component that need to be cooled, also known as the cooling area.

[0025] In this case, at least one guide recess (along the main extension plane) is formed in an edge area of ​​the carrier film in which the insulation mat has no filling material.

[0026] The guide recess makes it particularly easy and safe to install the proposed insulation mat.

[0027] In an advantageous embodiment of the insulation mats, it is further proposed that the insulation mat has a plurality of guide recesses, which are preferably arranged at opposite ends of the carrier film, and particularly preferably diagonally opposite.

[0028] According to this embodiment, in addition to a plurality of guide recesses, at least two of the guide recesses are arranged at opposite ends of the carrier film in the main plane of extension, for example along the length and / or width of the carrier film. Preferably, the guide recesses are arranged at diagonally opposite corners of the carrier film in the main plane of extension, i.e., opposite each other both lengthwise and widthwise.

[0029] At least one guidance recess is designed with at least one additional degree of freedom to a guidance direction as a complementary guidance tool.

[0030] According to this embodiment, at least one of the guide recesses is designed with an additional degree of freedom. The guide recess, therefore, is not only slidable onto a complementary guide element along the guide direction, which preferably corresponds to the insulation direction, but is also movable in a further direction. For example, the guide element is a pin with a round cross-section and the guide recess is an elongated hole.

[0031] Preferably, one, and particularly preferably only one, of the guide recesses is designed without an additional degree of freedom relative to the guide element. The guide element and the guide recess are preferably precisely fitted to each other and / or have the same cross-sectional shape.

[0032] In an advantageous embodiment of the insulation mats, it is further proposed that at least two of the guide recesses are designed or arranged differently in such a way that at least one of the two guide recesses cannot be applied to the complementary guide means for the other guide recess.

[0033] According to this embodiment, at least two of the guide recesses are designed or arranged differently in such a way that they can only be slid onto the guide means of the current-carrying component or an assembly of the component (for example, the battery junction box) if the insulation mat is correctly positioned relative to the current-carrying component.

[0034] For example, the two guide recesses have different cross-sectional shapes or sizes, are arranged at different distances from the edge of the carrier film and / or are arranged in such a way that further guide recesses cannot be slid onto their guide means if the positioning is incorrect, for example if the filling material is not positioned correctly in relation to the cooling area.

[0035] In a further advantageous embodiment of the insulation mats, it is proposed that the carrier film includes mounting tabs.

[0036] According to this embodiment, the carrier film has mounting tabs. For example, the mounting tabs are designed as extensions of the carrier film projecting beyond the assembly of the current-carrying component.

[0037] In a further advantageous embodiment of the insulation mats, it is proposed that the insulation mat be designed as a prefabricated component that can be assembled.

[0038] According to this embodiment, the insulation mat is designed as a pre-assembled component. In other words, the insulation mat can be mounted as a complete unit between the current-carrying component and the heat sink, for example by gluing and / or welding.

[0039] According to another aspect, a pre-assembly unit for the power electronics of a motor vehicle is proposed, comprising at least the following components: - a current-carrying component; and - an insulating mat attached to the current-carrying component according to an embodiment according to the above description, wherein complementary guiding means of the current-carrying component are incorporated in the guiding recesses of the insulation mat.

[0040] Here is a proposed pre-assembly unit for power electronics for a motor vehicle.

[0041] The pre-assembly unit includes a current-carrying component and an insulating mat as described above.

[0042] The current-carrying component generates power loss during operation, which must be dissipated in the form of heat. Furthermore, the current-carrying component must be electrically insulated from other components.

[0043] For example, the current-carrying component is a component of an assembly, preferably a battery junction box. For example, the current-carrying component is a busbar.

[0044] Preferably, the entire Battery Junction Box is included as a component of the current-carrying part of the pre-assembly unit.

[0045] The insulation mat is pre-mounted on the live component or its pre-assembly unit, for example, the battery junction box. For instance, the insulation mat is glued to the live component.

[0046] Preferably, such a current-carrying component or assembly has several cooling zones spaced apart from one another in the main plane of extension, which must be contacted by means of the filling material. The insulation mat has a corresponding number of gap pads or gap fillers arranged accordingly in the main plane of extension, which are in contact with the cooling sections in the pre-assembly unit. When the invention is described as having several filling materials, this does not refer to different materials in terms of their chemical composition, but rather to the structural presence of, for example, spatially separated filling materials, unless the context explicitly indicates otherwise.

[0047] The complementary guide elements of the current-carrying component are incorporated into complementary guide recesses in the insulation mat.

[0048] This allows for particularly easy assembly with precise positioning of the filling materials on the current-carrying components.

[0049] According to another aspect, a power electronics system for a motor vehicle is proposed, comprising at least the following components: - an insulation mat according to an embodiment as described above; - a current-carrying component; and - a heat sink; wherein the filling material of the insulation mat is arranged between the current-carrying component and the heat sink, and wherein complementary guiding means of the current-carrying component, its assembly, the heat sink and / or a housing in the Guide recesses of the insulation mat are included.

[0050] A power electronics system for a motor vehicle is proposed here. The power electronics system includes at least an insulating mat, a current-carrying component, and a heat sink.

[0051] For example, such power electronics include a battery junction box and a power control unit. The battery junction box, for example, includes fuses, contactors, and busbars or conductors to the individual components of the high-voltage network. The power control unit, for example, includes a power converter, such as an AC-DC converter or a DC-DC converter.

[0052] In this process, the electrical power losses of both the current-carrying component of the battery junction box, such as the busbars, and the current-carrying components of the power control unit, such as the power converters, must be dissipated by means of cooling. A common heat sink is used for this purpose. For example, the current-carrying component of the battery junction box is thermally coupled to the heat sink by means of the insulating mat's filler material, also known as a gap pad or gap filler.

[0053] The insulation mat is manufactured according to the preceding description. For example, the insulation mat is manufactured as a pre-assembled unit together with the current-carrying component, according to the preceding description.

[0054] The current-carrying component is a component that requires cooling. In other words, the current-carrying component generates power loss during operation, which must be dissipated in the form of heat. Therefore, the current-carrying component must be electrically insulated from other components.

[0055] For example, the current-carrying component is a component of the battery junction box, such as a busbar.

[0056] The heat sink is, for example, a cooling plate. Preferably, the heat sink is permeable by a cooling medium, for example, a dielectric or a water-based cooling medium. Preferably, such a cooling plate is arranged parallel to the main plane of extension.

[0057] The filling material is arranged along the insulation direction between the current-carrying component and the heat sink, thus bridging a gap between the current-carrying component and the heat sink to ensure good heat transfer.

[0058] Preferably, the filler material (in the main plane of extension) is arranged, particularly preferably completely, in an overlap region between the heat sink and the current-carrying component. For example, the overlap region is completely or only partially (along the main plane of extension) filled by the filler material. For example, the filler material is connected to the core material by means of a retaining section. For example, the remaining overlap region (along the main plane of extension) is covered by an edge section of the carrier film that surrounds the retaining section.

[0059] The overlap area refers to the area in which the current-carrying component and the heat sink overlap in the main extension plane.

[0060] Preferably, an edge section of the carrier film extends beyond the overlap area of ​​the heat sink and the current-carrying component. Preferably, the edge section extends beyond the overlap area (in the main plane of extension) at least far enough that current flow between the current-carrying component and the heat sink is prevented due to the extended creepage distance.

[0061] Preferably, the heat sink is larger than the current-carrying component in the main plane of extension. In such an embodiment, the filler material in the main plane of extension is, for example, flush with the current-carrying component, i.e., completely covering it, or smaller than it, i.e., covering only a portion of the current-carrying component. Preferably, the carrier film or edge sections of the carrier film are designed to extend beyond the current-carrying component to such an extent that the creepage distance prevents unwanted current flow. The edge sections are arranged in the main plane of extension around retaining sections in which the carrier film is in contact with the filler material.

[0062] The guide recesses of the insulation mat are accordingly pushed onto the complementary guide means formed by the battery junction box.

[0063] In an advantageous embodiment of the power electronics, it is further proposed that the current-carrying component is a component of a battery junction box, preferably a busbar.

[0064] In a further advantageous embodiment of the power electronics, it is proposed that the heat sink is integrated into a current control device on the side facing the current-carrying component.

[0065] For example, the current control device has a control housing. For example, the heat sink, preferably a cooling plate, is integrated into the current control device, preferably into the control housing. The heat sink is arranged on the side of the current control device facing the current-carrying component or battery junction box.

[0066] For example, the battery junction box has a box housing. Alternatively or additionally, the battery junction box and the current control unit are integrated into a common power electronics housing.

[0067] According to another aspect, a manufacturing process for power electronics according to an embodiment as described above is proposed, comprising the following steps: a. Providing the insulation mat; b. Sliding the guide recesses onto complementary guide means of the current-carrying component, the heat sink or a housing, c. Attaching the insulation mat to the current-carrying component or the heat sink, d. Pressing the respective opposite side of the insulation mat of the current-carrying component and heat sink against the fastening from step c.

[0068] Here is a proposed manufacturing process for power electronics of a motor vehicle, which includes at least the steps a., b., c. and d. explained in more detail below in the order given.

[0069] In step a., the insulation mat is provided as a pre-assembled, ready-to-install component. The insulation mat comprises the carrier film and the filling material, which are bonded together.

[0070] In step b., the guide recesses are slid onto the complementary guide elements, which are preferably formed by the battery junction box. The insulation mat is then correctly positioned in relation to the current-carrying components and / or the cooling areas so that the filling materials come into contact with them.

[0071] In step c., the insulation mat is attached either to the current-carrying component, preferably the battery junction box, or to the heat sink, for example by gluing.

[0072] Subsequently, in step d, the side opposite the insulation direction, i.e., the side facing away from the attachment in step c, is pressed against the other component. Thus, if the insulation mat was attached to the current-carrying component in step c, it is now pressed against the heat sink with the side facing away from the current-carrying component along the insulation direction and preferably attached to it.

[0073] The invention described above is explained in detail below against the relevant technical background with reference to the accompanying drawings, which show preferred embodiments. The invention is in no way limited by the purely schematic drawings, although it should be noted that the drawings are not dimensionally accurate and are not suitable for defining size relationships. It is illustrated in Fig. 1: a power electronics unit with an insulating mat; Fig. 2: a pre-assembly unit for power electronics according to Fig. 2 in a top view; Fig. 3: an insulation mat for a pre-assembly unit according to Fig. 2 in a top view; Fig. 4: an insulation mat for power electronics according to Fig. 1 in a schematic sectional view; Fig. 5: an alternative embodiment of the insulation mat according to Fig. 4 in a schematic sectional view; Fig. 6: an insulation mat after Fig. 4 with an additional adhesive layer in a schematic sectional view; and Fig. 7: an alternative embodiment of the insulation mat according to Fig. 4 in a schematic sectional view.

[0074] In Fig. Figure 1 shows a power electronics unit 2 with an insulating mat 1 in a sectional view. The power electronics unit 2 is part of a motor vehicle's high-voltage network and is designed to regulate the high-voltage network. For this purpose, the power electronics unit 2 includes a battery junction box 11 and a current control unit 14.

[0075] The Battery Junction Box 11 comprises fuses, contactors, and busbars 12 or conductors to the individual high-voltage components of the high-voltage network. The Battery Junction Box 11 thus includes a number of current-carrying components 9 of the high-voltage network, which must be cooled during operation due to the power loss during current flow.

[0076] The power control unit 14 includes, among other things, power converters, here an AC-DC converter and a DC-DC converter, and a heat sink 10, here designed as a cooling plate. A cooling medium can flow through the cooling plate to provide cooling. Thus, for example, the heat-generating components of the power control unit 14, such as the power converters, can be cooled. The heat sink 10 is arranged along an insulation direction 13 on one side facing the battery junction box 11.

[0077] Along the insulation direction 13, the insulation mat 1 is arranged between the battery junction box 11 and the current control device 14 or the heat sink 10.

[0078] Battery Junction Box 11 is also thermally connected to the heat sink 10 by means of the insulation mat 1 and can therefore be cooled by means of the heat sink 10. For example, individual current-carrying components 9 of the Battery Junction Box 11, such as the busbars 12, which have a high cooling requirement, are insulated by means of a filler material 4 (not shown here, see Figure 1). Fig. 2) the insulation mat 1 is thermally coupled to the heat sink 10.

[0079] The insulation mat 1 electrically insulates the current-carrying components 9 of the battery junction box 11 from the heat sink 10 or the current control unit 14.

[0080] Both the heat sink 10 and the insulation mat 1 are arranged parallel to a principal extension plane, which is arranged orthogonally to the insulation direction 13.

[0081] In Fig. 2 is a pre-assembly unit 8 for a power electronics 2 according to Fig. 1 in a top view. The pre-assembly unit 8 comprises a battery junction box 11 with a plurality of busbars 12 as current-carrying components 9. Filler material 4 is arranged section by section on the busbars 12 to conduct the heat from the power loss of the busbars 12 to the heat sink 10.

[0082] The filling material 4 is, as in relation to Fig. 1 explained, supported by a carrier film 3 which has retaining sections 15 in the area of ​​the filler material 4, to which the filler material 4 is attached to the carrier film 3. The filler material 4 is designed to increase the thermal conductivity in these areas.

[0083] Edge sections 16 of the carrier film 3 are arranged around and between the holding sections 15. The edge sections 16 ensure good electrical insulation even outside the cooling areas covered by the filling material 4, thus providing sufficiently long creepage distances.

[0084] Here, a plurality of filling materials 4, or gap pads or gap fillers, are held by means of a carrier film 3 (here only one is marked pars pro toto, compare Fig. 3) This makes it possible, as shown here, to mount the majority of the gap pads or gap fillers simultaneously in the desired positions. Thus, for example, the illustrated pre-assembly unit 8 can be manufactured.

[0085] The carrier film 3 has two guide recesses 5 as shown in the illustration. One guide recess 5 is located at the bottom left and the other at the top right. The guide recesses 5 are therefore arranged in a principal plane, orthogonal to the insulation direction 13, at diagonally opposite corners of the carrier film 3.

[0086] The guide recess 5 at the bottom left is designed as a round hole and is precisely aligned with a round guide element 6 of the battery junction box 11. The guide recess 5 at the top right is designed as an elongated hole on a round guide element 6 of the battery junction box 11, thus providing an additional degree of freedom, which simplifies assembly and avoids a double fit.

[0087] In Fig. 3 is an alternative insulation mat 1 for a pre-assembly unit 8 according to Fig. 2 shown in a top view.

[0088] Insulation mat 1 is essentially the same as insulation mat 1, which is in Fig. Figure 2 shows and explains above. Therefore, only the differences will be discussed here. In the illustrated insulation mat 1, both guide recesses 5 extend from an outer edge into the carrier film 3. The guide recess 5 located at the bottom left in the illustration extends from a lateral edge, and the guide recess 5 located at the top right in the illustration extends from a longitudinal edge. Thus, the carrier film 3 can only be slid onto the complementary guide elements 6 of the battery junction box 11 in the correct orientation. A Poka-Yoke system is therefore implemented by means of the guide recesses 5.

[0089] In addition, the carrier film 3 forms mounting tabs 7, which facilitate the mounting of the insulation mat 1 on the battery junction box 11 and the handling of the insulation mat 1.

[0090] In Fig. Figure 4 shows a schematic sectional view of an insulation mat 1. As shown on the right, a heat sink 10, in the form of a cooling plate, is indicated. A dielectric fluid or cooling water can flow through the heat sink 10 to dissipate the waste heat from a current-carrying component 9, for example, a busbar 12.

[0091] The insulation mat 1 is arranged between the heat sink 10 and the current-carrying component 9. The insulation mat 1 comprises a carrier film 3 and the filler material 4. The carrier film 3 includes a retaining section 15 and an edge section 16.

[0092] The filling material 4 is designed for thermal connection and electrical insulation between the heat sink 10 and the current-carrying component 9.

[0093] The carrier film 3 and the filling material 4 are connected to each other by the retaining section 15. As shown, the filling material 4 is arranged on one side of the carrier film 3 along the insulation direction 13. The carrier film 3 borders the cooling plate and is attached to it, for example, by gluing.

[0094] By means of the edge sections 16 of the carrier film 3, which extend beyond the holding sections 15, the creepage distance between the heat sink 10 and the current-carrying component 9 is increased to such an extent that an unwanted current flow is prevented.

[0095] In Fig. 5 is an alternative embodiment of the insulation mat 1 according to Fig. 4 shown in a schematic sectional view.

[0096] Unlike Fig. 4 The carrier film 3 is arranged adjacent to and attached to the current-carrying component 9. The filler material 4 is arranged accordingly along the insulation direction 13 between the carrier film 3 and the heat sink 10.

[0097] In Fig. 6 is an insulation mat 1 according to Fig. Figure 4 shows an additional adhesive layer 17 in a schematic sectional view. For example, the insulation mat 1 or the carrier film 3 has an adhesive layer 17 by means of which the insulation mat 1 can be bonded to the heat sink 10, for example as shown here.

[0098] In Fig. 7 is an alternative embodiment of the insulation mat 1 according to Fig. 4 shown in a schematic sectional view.

[0099] The retaining section 15 is perforated. The filler material 4 extends through the perforation of the retaining section 15. This increases the thermal conductivity in the area of ​​the retaining section 15. The filler material 4 is arranged along the insulation direction 13 on both sides of the carrier film 3. Thus, the filler material 4 is in direct contact with both the current-carrying component 9 and the heat sink 10, further improving heat dissipation.

[0100] An insulation mat with guide recesses in the carrier film is proposed, which simplifies assembly. Reference symbol list 1 insulation mat 2 Power Electronics 3 carrier film 4 Filling material 5 guide recess 6 Management tools 7 Mounting tab 8 Pre-assembly unit 9 current-carrying components 10 heat sinks 11 Battery Junction Box 12 busbar 13 Insulation direction 14 Power control device 15 Stop section 16 marginal section 17 adhesive layer

Claims

Insulation mat (1) for power electronics (2) of a motor vehicle, comprising at least the following components: - an electrically and thermally insulating carrier film (3); and - electrically insulating and thermally conductive filler material (4), wherein the carrier film (3) has at least one guide recess (5) by means of which the carrier film (3) can be aligned during assembly, characterized in that at least one guide recess (5) is formed with at least one additional degree of freedom to a guide direction to a complementary guide means (6). Insulation mat (1) according to claim 1, wherein the insulation mat (1) has a plurality of guide recesses (5). Insulation mat (1) according to one of the preceding claims, wherein at least two of the guide recesses (5) are designed or arranged differently such that at least one of the two guide recesses (5) cannot be applied to the complementary guide means (6) for the respective other guide recess (5). Insulation mat (1) according to one of the preceding claims, wherein the carrier film (3) comprises mounting tabs (7). Insulation mat (1) according to one of the preceding claims, wherein the insulation mat (1) is designed as a mountable prefabricated component. Pre-assembly unit (8) for power electronics (2) of a motor vehicle, comprising at least the following components: - a current-carrying component (9); and - an insulating mat (1) attached to the current-carrying component (9) according to any one of claims 1 to 5, wherein complementary guide means (6) of the current-carrying component (9) are received in the guide recesses (5) of the insulating mat (1). Power electronics (2) for a motor vehicle, comprising at least the following components: - an insulating mat (1) according to any one of claims 1 to 5; - a current-carrying component (9); and - a heat sink (10); wherein the filling material (4) of the insulating mat (1) is arranged between the current-carrying component (9) and the heat sink (10), and wherein complementary guiding means (6) of the current-carrying component (9), its assembly, the heat sink (10) and / or a housing are received in the guiding recesses (5) of the insulating mat (1). Power electronics (2) according to claim 7, wherein the current-carrying component (9) is a component of a battery junction box (11). A manufacturing method for a power electronics device (2) according to claim 7 or claim 8, comprising the following steps: a. providing the insulation mat (1); b. sliding the guide recesses (5) onto complementary guide means (6) of the current-carrying component (9), the heat sink (10), or a housing; c. attaching the insulation mat (1) to the current-carrying component (9) or the heat sink (10); and d. pressing the respective other sides of the current-carrying component (9) and the heat sink (10) against the side of the insulation mat (1) opposite the attachment from step c.

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