Insertion Module and Module Assembly

Abstract

The present invention relates to an insert module (10) and a module assembly (1) for a vehicle having such an insert module (10), as well as a method for forming an external thermal interface (17) of such an insert module (10), the module (10) including a module housing (11), at least one heat dissipation device (12), and at least one electrical component (15) disposed on a printed circuit board (14), the module housing (11) at least partially surrounding the printed circuit board (14), the at least one heat dissipation device (12) having at least one internal thermal interface (16) on a surface facing the at least one electrical component (15) and configured to thermally couple the at least one electrical component (15) to the at least one heat dissipation device (12), and the at least one The at least one heat dissipation device (12) has, on a surface opposite the at least one electrical component (15), at least one external thermal interface (17) configured to thermally couple the at least one heat dissipation device (12) with an external heat sink (8), the at least one external thermal interface (17) including at least one thermally conductive and elastic compensation element (18) connected to the at least one heat dissipation device (12) and configured to be compressed during formation of the corresponding external thermal interface (17), and at least one thermally conductive and slidable contact connection element (19) attached to the thermally conductive and elastic compensation element (18) and forming a thermal contact connection surface of the external thermal interface (17) with the external heat sink (8) and configured to compress the at least one thermally conductive and elastic compensation element (18).

Description

[Technical field]

[0001] The present invention relates to an insert module, in particular for a module assembly in a vehicle, and also to a module assembly, in particular for a vehicle, comprising at least one such insert module, and to a method for forming the external thermal interface of such an insert module. [Background technology]

[0002] In order to operate electrical assemblies or modules, such as control devices, power output stages, or individual electrical components, such as power semiconductors, processors, microcontrollers, etc., within a predefined temperature range, various heat dissipation techniques are known from the prior art, where the thermal coupling of the component as heat source with a heat sink, such as a cooling device, has a high influence.

[0003] For example, from the applicant's subsequently published German patent application DE 10 2021202654 A1, a heat dissipation device, in particular for a control unit assembly in a vehicle, is known which comprises a receiving space which is open on at least one side and at least one mosaic segment which is arranged in the receiving space and which comprises a thermally conductive and elastic compensation element and a thermally conductive, low-adhesive contact-connection area. The at least one mosaic segment is arranged in the receiving space in such a way that the thermally conductive and elastic compensation element of the at least one mosaic segment rests against an inner surface of the bottom of the receiving space and at least the thermally conductive, low-adhesive contact-connection area of ​​the at least one mosaic segment partially protrudes out of the receiving space on the open side of the receiving space opposite the bottom. Here, the outer surface of the bottom of the receiving space forms a rigid first contact-connection surface for a heat source or a heat sink and the thermally conductive, low-adhesive contact-connection area of ​​the at least one mosaic segment forms a flexible second contact-connection surface for a heat sink or a heat source.

[0004] Furthermore, from the subsequently published German patent application DE 102021203625 A1, an electronic assembly for a motor vehicle is known, which comprises at least one electronic unit with at least one electronic component and at least one housing surrounding the electronic unit with the electronic component. The electronic component forms a thermally conductive connection with the housing. Here, at least one heat sink or a highly thermally conductive component is arranged on the outside of the housing for heat dissipation of the electronic component. Furthermore, German patent application DE 102021203625 A1 discloses a device for housing an exchangeable electronic assembly, which comprises at least one housing made of a thermally conductive material at least partially surrounding the exchangeable electronic assembly. Furthermore, a front face is provided which is detachably connected to the housing, via which front face access is possible to the exchangeable electronic assembly arranged inside the housing. For cooling the exchangeable electronic assembly, at least one cooler is arranged on at least one outer surface of the housing. The rear housing cover includes at least one through hole portion for at least one plug and / or at least one shield and / or at least one receiving portion for a rear wall printed circuit board oriented parallel to the housing cover and used for contact connection of a replaceable electronic assembly. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] DE 102021202654 [Patent Document 2] DE 102021203625 A1 Summary of the Invention [Problem to be solved by the invention]

[0006] Disclosure of the Invention The insert module with the features of independent claim 1 and the module assembly with the features of independent claim 9 each have the advantage that the at least one external thermal interface allows a larger connection surface to the external heat sink. This allows a higher heat dissipation performance to be achieved. Alternatively, for a comparable heat dissipation performance, a reduced contact connection area is required for heat dissipation. Furthermore, non-uniformities between the heat dissipation device and the external heat sink can be compensated for by at least one thermally conductive and elastic compensation element of the at least one external thermal interface. Due to the improved heat transfer, the life of the electric component as a heat source can be extended. Due to the at least one thermally conductive and slidable contact connection element of the at least one external thermal interface, the at least one thermally conductive and elastic compensation element can be easily pulled away again from the corresponding contact connection surface of the heat sink without any part of the at least one thermally conductive and elastic compensation element remaining on the contact connection surface of the heat sink. Furthermore, the at least one thermally conductive and elastic compensation element allows a larger tolerance in the contact connection surface of the heat dissipation device and the external heat sink. This allows a further reduction in the manufacturing costs. [Means for solving the problem]

[0007] An embodiment of the present invention provides an insert module, in particular for module assembly in a vehicle, comprising a module housing, at least one heat dissipation device, and at least one electrical component arranged on a printed circuit board. The module housing at least partially surrounds the printed circuit board. The at least one heat dissipation device has at least one internal thermal interface on a surface facing the at least one electrical component, the at least one internal thermal interface being configured to thermally couple the at least one electrical component to the at least one heat dissipation device. The at least one heat dissipation device also has at least one external thermal interface on a surface opposite the at least one electrical component, the at least one external thermal interface being configured to thermally couple the at least one heat dissipation device to an external heat sink. Here, the at least one external thermal interface includes at least one thermally conductive and elastic compensation element connected to the at least one heat dissipation device and configured to be compressed when forming the corresponding external thermal interface, and at least one thermally conductive and slidable contact connection element attached to the at least one thermally conductive and elastic compensation element and forming a thermal contact connection surface of the external thermal interface with the external heat sink and configured to compress the at least one thermally conductive and elastic compensation element.

[0008] Also proposed is a module assembly, in particular for a vehicle, with a housing in which a rear wall printed circuit board, at least one external heat sink and at least one plug-in point are arranged and at least one such insert module, where the at least one insert module is inserted into a corresponding receiving opening of the housing in such a way that at the corresponding plug-in point the insert module is held form-fittingly and frictionally between a first contact-connection surface and a second contact-connection surface of the receiving opening, and where the at least one thermally conductive and elastic compensation element compressed by the insertion action forms together with the at least one thermally conductive and slidable contact-connection element at least one external thermal interface to the at least one external heat sink, so that heat generated by at least one electrical component of the insert module can be dissipated directly to the at least one external heat sink via the at least one internal thermal interface, the at least one heat dissipation device and the at least one external thermal interface.

[0009] Furthermore, a method for forming the external thermal interface of such an insert module is proposed, said method comprising the following steps: Providing an insertion module; applying at least one thermally conductive and elastic compensation element to a surface of the at least one heat dissipation device opposite the at least one electrical component; - connecting a first end region of the at least one thermally conductive, slidable contact-connection element, which is located on the front side in the insertion direction, with at least one heat dissipation device; - applying at least one thermally conductive, slidable contact-connection element to at least one thermally conductive, elastic compensation element; Includes.

[0010] The external thermal interface embodiments compensate for non-uniform tolerances to the external heat sink, allowing for good heat transfer acceptance in the presence of surface non-uniformities and particles between surfaces, without creating a permanent air gap between the heat dissipation device and the external heat sink.

[0011] An insert module may in the following be understood to mean, in particular, an electronic assembly which performs computationally intensive functions in the automotive sector and can be used, for example, for semi-autonomous or autonomous driving functions, communication functions, gateway functions, infotainment functions, safety functions, etc. The associated electrical components include high-performance processors, multi-core processors or highly integrated circuits (SoC, system on chip) or power semiconductors which are characterized by high power losses. The configuration as an insert module allows easy interchangeability within a corresponding module assembly and also allows the retrofitting of current hardware by correspondingly replacing or inserting the electronic assembly.

[0012] Heat dissipation device is understood in the following to mean a part with particularly good thermal conductivity, which can be formed, for example, as a die-cast part, in particular an aluminum die-cast part, or as an extrusion part or sheet metal part.

[0013] The measures and developments recited in the dependent claims enable advantageous developments of the insert module as recited in independent patent claim 1 and of the module assembly as recited in independent patent claim 9, in particular of a module assembly for vehicles.

[0014] Particularly preferably, the at least one external thermal interface can be arranged in an accommodation space of the at least one heat dissipation device, whereby the at least one thermally conductive, slidable contact-connection element can completely protrude from the accommodation space and the at least one thermally conductive, elastic compensation element can at least partially protrude from the accommodation space, whereby the depth of the accommodation space can represent the maximum extent beyond which the at least one thermally conductive, elastic compensation element cannot be compressed any further.

[0015] In a preferred embodiment of the insert module, the at least one thermally conductive and elastic compensation element may be inseparably connected to the at least one heat dissipation device. Preferably, the at least one thermally conductive and elastic compensation element may be connected to the heat dissipation device by adhesive. Alternatively, other suitable connection techniques may be used.

[0016] In a further preferred embodiment of the insertion module, the at least one thermally conductive and elastic compensation element may be configured as a gap filler. For example, a commercially available silicone-based self-adhesive mat with good thermal conductivity and a thickness of 1.52 mm may be used as the thermally conductive and elastic compensation element. This allows for example to compensate for non-uniformities in the range of about ±0.2 mm. The at least one thermally conductive and elastic compensation element may be configured as a flat mat or strip, for example.

[0017] In a further preferred embodiment of the insert module, the at least one thermally conductive slidable contact-connection element may be configured as a strip or plate. The at least one thermally conductive slidable contact-connection element consists of a very thin and tear-resistant material, which does not have to be specially treated for this purpose. For example, brass, copper, aluminum, carbon (carbon fiber), graphite or spring steel can be used as this material. The at least one thermally conductive slidable contact-connection element can be present, for example, as a very thin rolled sheet or as a carbon fiber mat with a thickness of about 0.02 mm to 0.1 mm. As an alternative to a large-area thermally conductive slidable contact-connection element, it is also possible to apply several strips of thermally conductive slidable contact-connection elements in order to enhance the compensation of non-uniformities and particles. These strips can be produced, for example, as rolled or laser-cut parts and can have a width, for example, between 5 mm and 20 mm. Therefore, there is a high degree of geometric freedom, so that these strips can be easily adapted to the requirements in terms of geometry or material selection, area share in the total cooling surface, etc. At least one thermally conductive, slidable contact-connection element can be easily moved away from the contact-connection surface of the heat sink, since the at least one thermally conductive, elastic compensation element is sufficiently covered by the individual strips or plates. Here, the external thermal interface can be adapted to the unevenness of the surface on the basis of the at least one thermally conductive, elastic compensation element that is compressible. This allows contact connections to be obtained over a large area, even with uneven connection surfaces, and therefore with good heat transfer. Furthermore, a high level of robustness against contamination can be obtained, since individual dirt particles in the gaps between the individual strips of the thermally conductive, slidable contact-connection element can only prevent the individual strips from abutting. This ensures an even better heat transfer of all other strips. The intervening spaces between the strips can be used as "volume buffers". In the case of particles or local inhomogeneities, these spaces can be used, for example, as volume compensation for the adhesive medium that holds the strip in place on the at least one thermally conductive and elastic compensation element.

[0018] Further solutions are also conceivable, for example, by providing at least one thermally conductive, slidable contact-connection element with holes that allow the at least one thermally conductive, elastic compensation element to obtain a direct contact connection with the heat sink. Ideally, the material is only pushed through the openings after the end of the mounting process or by peeling off the film so that it is no longer in the way. According to this principle, some additional transition resistance is saved. However, this method is only effective if the thermal resistance of the material of the at least one thermally conductive, elastic compensation element is smaller than the sum of the thermal resistance and the transition resistance of the at least one thermally conductive, slidable contact-connection element.

[0019] In a further preferred embodiment of the insert module, the at least one thermally conductive, slidable contact-connection element can be connected with a first end region, which is located at the front in the insertion direction, to the at least one heat dissipation device. This can be advantageously prevented in the event of the insertion of the insert module from falling off the at least one thermally conductive, elastic compensation element. This means that the first connection in the first end region can withstand the frictional forces when the insert module is plugged in. Alternatively, the at least one thermally conductive, slidable contact-connection element can be connected with the at least one heat dissipation device in two end regions. An additional second connection in the second end region can withstand the frictional forces when the insert module is pulled out. Laser welding can preferably be used as a joining technique. Of course, other suitable joining methods, such as welding, toxing, riveting, screwing, clamping or brazing, are also conceivable, again depending on the material combination.

[0020] In a preferred embodiment of the module assembly, the at least one heat sink may be configured as a cooling device, wherein the at least one receiving opening may be formed in the cooling device.

[0021] In a further preferred embodiment of the module assembly, the at least one cooling device may have a plurality of cooling elements, where the at least one cooling element may be arranged between two receiving openings arranged next to each other. The at least one cooling element may be configured, for example, as a metal plate into which at least one cooling channel is introduced, whereby water or another suitable coolant can be introduced, for example, in order to enable dissipation of heat generated by the at least one electrical component. Alternatively, the cooling element may be configured, for example, as a so-called evaporation chamber, heat pipe, pulsating heat pipe.

[0022] In a preferred embodiment of the module assembly, the insert module has at least one plug which, when inserted, may plug into a corresponding plug receptacle in the rear wall printed circuit board.

[0023] The mounting principle of the module assembly according to the invention consists in that an insert module, such as a drawer, can be inserted into the associated receiving opening at a corresponding plug-in point. Here, the insert module is inserted into the receiving opening until at least one plug of the insert module is plugged into a corresponding plug-in receptacle of the rear wall printed circuit board. The sliding force used during the insertion process of the insert module generates a compressive force acting perpendicularly to the sliding direction, which compresses at least one thermally conductive and elastic compensation element of at least one external thermal interface. Of course, the force required to insert the insert module into the receiving opening should be as small as possible, so that the friction counter-part can be configured accordingly.

[0024] Exemplary embodiments of the invention are illustrated in the drawings and explained in more detail in the following description, in which identical reference numbers represent components or elements performing the same or similar functions. [Brief description of the drawings]

[0025] [Figure 1] 1 is a schematic cross-sectional view of a module assembly according to the invention, in particular a module assembly for a vehicle, together with an embodiment of an insert module according to the invention; [Diagram 2] 2 is a schematic cross-sectional view of the insertion module according to the invention of FIG. 1 from below; [Diagram 3] 3 is a flow chart that illustrates a schematic diagram of one embodiment of a method according to the present invention for forming an external thermal interface of the insert module of FIGS. 1 and 2; [Figure 4] 4 shows a schematic cross-sectional view of the inventive insertion module of FIGS. 1 and 2 during the inventive method of FIG. 3; FIG. [Diagram 5] 4 shows a schematic cross-sectional view of the inventive insertion module of FIGS. 1 and 2 during the inventive method of FIG. 3; FIG. [Figure 6] 4 shows a schematic cross-sectional view of the inventive insertion module of FIGS. 1 and 2 during the inventive method of FIG. 3; FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0026] EMBODIMENTS OF THE PRESENTINVENTION As is evident from Fig. 1, the illustrated embodiment of a module assembly 1 according to the invention, in particular a module assembly 1 for a vehicle, comprises a housing 3 in which a rear wall printed circuit board 5, at least one heat sink 8 and at least one plug-in point 6 are arranged, and at least one insert module 10 which is inserted into a corresponding receiving opening 9 of the housing 3 in such a way that the insert module 10 is held form-fittingly and frictionally between a first contact-connection surface 9.1 and a second contact-connection surface 9.2 of the receiving opening 9 at the corresponding plug-in point 6. Here, at least one thermally conductive and elastic compensation element 18 which is compressed by the insertion movement forms together with at least one thermally conductive and slidable contact-connection element 19 at least one external thermal interface 17 to at least one external heat sink 8, so that heat generated by at least one electrical component 15 of the at least one insert module 10 can be dissipated directly to at least one external heat sink 8 via the at least one internal thermal interface 16, the at least one heat dissipation device 12 and the at least one external thermal interface 17.

[0027] The cross-section of the module assembly 1 shown in Fig. 1 shows two plug-in points 6a, 6b into which one insert module 10 can be inserted in each. Fig. 1 also shows two insert modules 10, where a first insert module 10A is already inserted into its envisaged plug-in point 6A and a second insert module 10B is to be inserted into its envisaged plug-in point 6B.

[0028] 1, each of the illustrated insert modules 10, 10A, 10B includes a module housing 11, at least one heat dissipation device 12, and at least one electrical component 15 disposed on a printed circuit board 14, where the module housing 11 at least partially surrounds the printed circuit board 14. The at least one heat dissipation device 12 has at least one internal thermal interface 16 on a surface facing the at least one electrical component 15, thermally coupling the at least one electrical component 15 to the at least one heat dissipation device 12. Additionally, the at least one heat dissipation device 12 has at least one external thermal interface 17 on a surface opposite the at least one electrical component 15, thermally coupling the at least one heat dissipation device 12 to an external heat sink 8. Here, the at least one external thermal interface 17 includes at least one thermally conductive and elastic compensation element 18 that is connected to the at least one heat dissipation device 12 and is compressible when forming the corresponding external thermal interface 17, and at least one thermally conductive and slidable contact connection element 19 that is attached to the at least one thermally conductive and elastic compensation element 18 and forms a thermal contact connection surface of the external thermal interface 17 to the external heat sink 8 and compresses the at least one thermally conductive and elastic compensation element 18.

[0029] As is further evident from FIG. 1, the insert modules 10A, 10B in the illustrated embodiment of the module assembly 1 each comprise only one heat dissipation device 12, which at the same time forms the housing bottom 11A of the housing 11. In the illustrated cross-section of the insert modules 10A, 10B, two electric components 15 are respectively arranged on a printed circuit board 14, which is mechanically connected to the heat dissipation device 12 via at least one fastening element 14.2. Here, the first electric component 15 is configured as a power semiconductor 15A, which is connected to the heat dissipation device 12 via a first internal thermal interface 16A. The second electric component 15 is configured as a power processor 15B, which is connected to the heat dissipation device 12 via a second internal thermal interface 16B. Alternatively, it is also possible for the printed circuit board 14 to be arranged and held between the two parts of the housing 11 in the manner of a “sandwich”. These internal thermal interfaces 16, 16A, 16B can consist, for example, of a thermally conductive material, also called thermal interface material (TIM). The thermally conductive material can preferably be a thermally conductive elastomer. Moreover, the heat dissipation devices 12 of the illustrated insert modules 10A, 10B each include only one external thermal interface 17 arranged in the receiving space 13 of the at least one heat dissipation device 12. Here, the receiving space 13 is configured as a recess, in which case the at least one thermally conductive slidable contact-connection element 19 projects completely from the receiving space 13 and the at least one thermally conductive elastic compensation element 18 projects at least partially from the receiving space 13. In the illustrated embodiment, the at least one thermally conductive elastic compensation element 18 is configured as a gap filler 18A and is inseparably connected to the heat dissipation device 12 by means of an adhesive connection. In the illustrated embodiment, the gap filler 18A has a height H1 of about 1.52 mm in the normal state. The receiving space 13 has a height HA of about 0.9 mm to the mounting edge. This height HA represents the maximum extent to which the gap filler 18A cannot be compressed any further. This means that the height H2 of the gap filler 18A in the compressed state can be as small as 0.9 mm.This results in a tolerance for the non-uniformity that can still be tolerated in the two surfaces for their connection.

[0030] As is further apparent from FIG. 2, the insert module 10, in the illustrated embodiment of the module assembly 1, has six thermally conductive, slidable contact connection elements 19, each configured as a strip 19A, which are arranged on a thermally conductive, elastic compensation element 18, each configured as a strip, so that six thermally conductive, slidable contact connection elements 19 are arranged on six thermally conductive, elastic compensation elements 18.

[0031] In an alternative embodiment not shown, the at least one thermally conductive and elastic compensation element 18 is configured as a flat mat on which six thermally conductive and slidable contact connection elements 19 configured as strips 19A are arranged.

[0032] In a further embodiment, not shown, the at least one thermally conductive, slidable contact-connection element 19 is provided with at least one hole.

[0033] As can be seen further from Figures 1 and 2, the thermally conductive, slidable contact-connection elements 19 are each connected in a first end region 19.1, which is located on the front side in the insertion direction, via a first connection 20A with the heat dissipation device 12. As can be seen further from Figure 1, the thermally conductive, slidable contact-connection elements 19 can also be optionally connected in a second end region 19.2 with at least one heat dissipation device 12 via a second connection, respectively. These connections 20A, 20B are configured, for example, as laser welded joints 20.

[0034] As can be seen further from FIG. 1, at least one heat sink 8 is configured as a cooling device 8A with a number of cooling elements 8.1. Furthermore, receiving openings 9 are formed in this cooling device 8A, with at least one cooling element 8.1 being arranged between two receiving openings 9 arranged next to one another. In the illustrated exemplary embodiment, these cooling elements 8.1 are configured as metal plates, with the cooling element 8.1 arranged between two adjacent receiving openings 9 further having a cooling channel 8.2 led into the metal plate in the illustrated exemplary embodiment. The cooling device 8A is fixedly connected to the housing 3, so that the receiving openings 9 are arranged stationary with respect to the plug-in points 6, 6A, 6B. This means that the receiving openings 9 do not move even when inserting the insert modules 10, 10A, 10B.

[0035] As can be seen further from Fig. 1 and Fig. 2, the insert modules 10, 10A, 10B each have a number of plugs 14.1, which, as the first insert module 10A shown in Fig. 1 shows, are plugged into corresponding plug-in receptacles 5.1 of the rear-wall printed circuit board 5 in the inserted state. The inserted or plugged-in insert module 10, here the first insert module 10A, is electrically contact-connected via the plug-in receptacles 5.1 of this rear-wall printed circuit board 5. The plugged-in insert modules 10, 10A, 10B can also be electrically connected to one another via the rear-wall printed circuit board 5. As can be seen further from Fig. 1, the cooling device 8A is arranged in the housing 3 in such a way that the end region of the inserted insert module 10A, in which the plugs 14.1 are arranged, is held in the receiving opening 9 in a frictionally and form-locking manner. The housing 3 comprises, in addition to the illustrated cover 3.1 and the illustrated rear wall 3.2, side walls and a bottom, which are not shown in more detail, as well as a bottom, which is not shown.

[0036] The mounting principle of the module assembly 1 consists in that these insert modules 10A, 10B can be inserted in the housing 3 in the longitudinal direction y without tools, like a drawer. As is further evident from FIG. 1, the illustrated second insert module 10B is pre-centered during insertion by means of a small insert bevel 9.3 at the receiving opening 9, which has an intentional play of, for example, about 0.6 mm. This means that the housing 11 of the second insert module 10 and the thermally conductive, slidable contact-connection element 19 come into contact with the insert bevel 9.3 after a short insertion movement, for example of about 10 mm, whereby the subsequent thermally conductive, elastic compensation element 18, with an oversize of, for example, about 0.3 mm, starts to press the second insert module 10B against the second contact-connection surface 9.2, whereby the second insert module 10B is centered in the height direction z. After completion of this centering process, the actual sliding of the thermally conductive, slidable contact-connection element 19 starts. Here, a sliding force FS applied in the longitudinal direction y causes a compression force FK acting in the height direction z, which compresses the thermally conductive, elastic compensation element 18 via the thermally conductive, slidable contact-connection element 19. Here, the second insert module 10 slides over the first and second contact-connection surfaces 9.1, 9.2 of the heat sink 8 towards the plug receptacle 5.1 of the rear-wall printed circuit board 5, which is also configured or positioned on the rear-wall printed circuit board 5 and aligned with the second contact-connection surface 9.2, such that a deformation is caused in the circuit board 14 or the plug 14.1 or the plug receptacle 5.1. When the end position is reached, an electrical connection is made between the rear-wall printed circuit board 5 and the second insert module 10B. This compressive force FK, maintained by the 0.3 mm compression of the thermally conductive and elastic compensation element, acts on the plugged in first insert module 10A, thereby causing the external thermal interface 17 to create a good thermal transition between the heat dissipation device 12 and the heat sink 8.

[0037] In the illustrated embodiment of the module assembly 1, the thermal path between the inserted first insert module 10A and the cooling element 8.1 with the corresponding cooling channel includes the transition resistance of the bonded gap filler 18A, which can be influenced by the formation of the external thermal interface 17, thermal conduction in the gap filler 18A, which can be determined by material selection, thermal transition to the thermally conductive slidable contact connection element 19, which can be influenced by the formation of the external thermal interface 17, thermal conduction in the thermally conductive slidable contact connection element 19, which can be influenced by the selection of raw materials but also affects the friction value, and thermal transition from the thermally conductive slidable contact connection element 19 to the cooling element 8.1, which can be positively influenced by the compensation of tolerances and non-uniformities.

[0038] The elastic compensation element 18 in combination with a slidable contact element having a low sliding friction coefficient in the range of 0.1 to 0.3 makes it possible to create a larger contact area for heat transfer with good tolerance compensation.

[0039] As can be seen from Fig. 3, the method 100 for forming an external thermal interface 17 of an insert module 10 according to the invention comprises a step S100 of preparing an insert module 10. In step S110, at least one thermally conductive and elastic compensation element 18 is applied to the surface of the at least one heat dissipation device 12 facing away from the at least one electrical component 15. As can be seen from Fig. 4, in the illustrated embodiment, the at least one thermally conductive and elastic compensation element 18 is applied and bonded to the heat dissipation device 12 via a shear movement, the inclusion of air bubbles being avoided. In step S120, a first end region 19.1 of the at least one thermally conductive, slidable contact-connection element 19, which is located on the front side in the insertion direction, is connected to the at least one heat dissipation device 12. As can be seen further from Fig. 5, a first end region 19.1 on the front side of the at least one thermally conductive, slidable contact element 19 is joined to the at least one heat dissipation device 12 by means of laser welding in the illustrated embodiment. Subsequently, in step S130, the at least one thermally conductive, slidable contact-connection element 19 is applied to the at least one thermally conductive, elastic compensation element 18. As can be seen further from Fig. 6, the at least one thermally conductive, slidable contact-connection element 19 is applied and bonded to the at least one thermally conductive, elastic compensation element 18 by a shear movement, whereby the inclusion of air bubbles is avoided.

[0040] Optionally, in a step S140, indicated by dashed lines, it is also possible to connect the second end region 19.2 of the at least one thermally conductive, slidable contact-connection element 19 with the heat dissipation device 12.

Claims

1. An insertion module (10) comprising a module housing (11), at least one heat dissipation device (12), and at least one electrical component (15) arranged on a printed circuit board (14), The module housing (11) at least partially surrounds the printed circuit board (14); the at least one heat dissipation device (12) has at least one internal thermal interface (16) on a surface facing the at least one electrical component (15) configured to thermally couple the at least one electrical component (15) to the at least one heat dissipation device (12); the at least one heat dissipation device (12) has at least one external thermal interface (17) on a surface opposite the at least one electrical component (15) and configured to thermally couple the at least one heat dissipation device (12) to an external heat sink (8); the at least one external thermal interface (17) comprises at least one thermally conductive and elastic compensation element (18) connected to the at least one heat dissipation device (12) and configured to be compressed during formation of the corresponding external thermal interface (17), and at least one thermally conductive and slidable contact connection element (19) attached to the thermally conductive and elastic compensation element (18) and forming a thermal contact connection surface of the external thermal interface (17) to the external heat sink (8) and configured to compress the at least one thermally conductive and elastic compensation element (18), An insertion module (10).

2. 2. The insertion module (10) according to claim 1, wherein the at least one external thermal interface (17) is arranged in a receiving space (13) of the at least one heat dissipation device (12), the at least one thermally conductive, slidable contact connection element (19) protrudes completely, and the at least one thermally conductive, elastic compensation element (18) protrudes at least partially from the receiving space (13).

3. 3. The insert module (10) according to claim 1 or 2, wherein the at least one thermally conductive elastic compensation element (18) is inseparably connected to the at least one heat dissipation device (12).

4. The insert module (10) of any one of claims 1 to 3, wherein the at least one thermally conductive elastic compensation element (18) is configured as a gap filler (18A).

5. 5. The insert module (10) according to any one of the preceding claims, wherein the at least one thermally conductive, slidable contact-connection element (19) is configured as a strip or a plate.

6. 6. The insert module (10) according to claim 5, wherein the at least one thermally conductive, slidable contact-connection element (19) is provided with at least one hole.

7. 7. The insertion module (10) according to claim 1, wherein the at least one thermally conductive, slidable contact element (19) is connected to the at least one heat dissipation device (12) in a first end region (19.1) located on the front side in the insertion direction.

8. 8. The insert module (10) according to claim 7, wherein the at least one thermally conductive, slidable contact-connection element (19) is connected with the at least one heat dissipation device (12) in two end regions (19.1, 19.2).

9. The insertion module (10) is an insertion module (10) for a module assembly (1) in a vehicle, as described in any one of claims 1 to 8.

10. a housing (3) in which a rear wall printed circuit board (5), at least one external heat sink (8) and at least one plug-in point (6) are arranged; At least one insertion module (10) according to any one of claims 1 to 9, A module assembly (1) comprising: the at least one insert module (10) is inserted into a corresponding receiving opening (9) of the housing (3) in such a way that, at a corresponding plug-in point (6), the insert module (10) is held positively and frictionally between a first contact-connection surface (9.1) and a second contact-connection surface (9.2) of the receiving opening (9), at least one thermally conductive and elastic compensation element (18) compressed by the insertion action forms, together with at least one thermally conductive and slidable contact-connection element (19), at least one external thermal interface (17) to said at least one external heat sink (8), so that heat generated by at least one electrical component (15) of said insertion module (10) can be dissipated directly to said at least one external heat sink (8) via at least one internal thermal interface (16), at least one heat dissipation device (12) and said at least one external thermal interface (17). Module Assembly (1).

11. 11. The module assembly (1) according to claim 10, wherein the at least one external heat sink (8) is configured as a cooling device (8A).

12. 12. A module assembly (1) according to claim 11, wherein at least one receiving opening (9) is formed in the cooling device (8A).

13. 13. A module assembly (1) according to claim 11 or 12, wherein the at least one cooling device (8A) has a plurality of cooling elements (8.1), the at least one cooling element (8.1) being arranged between two receiving openings (9) arranged adjacent to each other.

14. 14. A module assembly (1) according to claim 13, wherein the at least one cooling element (8.1) is configured as a metal plate in which at least one cooling channel (8.2) is introduced.

15. 15. The module assembly (1) according to any one of claims 10 to 14, wherein the insert module (10) has at least one plug (14.1) which, in the inserted state, is plugged into a corresponding plug receiving portion (5.1) of the rear wall printed circuit board (5).

16. The module assembly (1) described in any one of claims 10 to 15, wherein the module assembly (1) is a module assembly (1) for a vehicle.

17. A method (100) for forming an external thermal interface (17) of an insert module (10) according to any one of claims 1 to 9, comprising the steps of: Providing the insertion module (10); applying at least one thermally conductive and elastic compensation element (18) to a surface of the at least one heat dissipation device (12) opposite the at least one electrical component (15); - connecting a first end region (19.1) of at least one thermally conductive, slidable contact-connection element (19) which is located on the front side in the insertion direction with said at least one heat dissipation device (12); - applying said at least one thermally conductive, slidable contact-connection element (19) to said at least one thermally conductive, elastic compensation element (18); The method (100) comprising:

Images