Adapter Potting Layout for Compact Thermal Management
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Solution Overview
Problem
Conventional chargers face challenges in achieving a smaller size and lighter weight while maintaining effective heat dissipation and preventing excessive temperature exposure, which can lead to component malfunction or damage.
Innovation Solution
The electric appliance features a case with a partition wall that separates two spaces, allowing the potting pattern with high thermal conductivity to fill only the space where heat generation occurs, while the second space remains empty, reducing overall weight and preventing fluid from entering unnecessary areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the case is used as a heat sink to dissipate internal heat, then heat dissipation is improved, but the surface temperature becomes too high causing low-temperature burn to users
Solution Approach 1:
The case is divided into a first case portion and a second case portion with different thermal conductivities. The first case portion has high thermal conductivity for heat dissipation, while the second case portion has low thermal conductivity to maintain low surface temperature for user safety.
Solution Approach 2:
Different portions of the case have different thermal properties tailored to their specific functions. The first case portion is designed with high thermal conductivity material for heat dissipation, while the second case portion uses low thermal conductivity material to remain cool to the touch.
2Volume of moving object
If the charger size is reduced to achieve smaller and lighter design, then portability is improved, but heat dissipation capability deteriorates and internal components are exposed to excessively high temperatures
Solution Approach 1:
The internal space is segmented into a first space filled with high thermal conductivity fluid for heat dissipation and a second space left empty or filled with low thermal conductivity material. This allows concentrated heat management in the critical area while maintaining compact overall size.
Solution Approach 2:
High thermal conductivity fluid is selectively applied only in the first space where heat generation occurs, providing targeted heat dissipation where needed most, while the rest of the charger maintains compact dimensions.
3Temperature
If high thermal conductivity fluid is injected into the case to improve heat dissipation, then heat dissipation efficiency is improved, but the charger weight increases
Solution Approach 1:
The case is divided into a first space for high thermal conductivity fluid and a second space that remains empty or contains low-density material. This segmentation allows the fluid to be confined to only the necessary volume for heat dissipation, minimizing weight increase.
Solution Approach 2:
Instead of filling the entire case with high thermal conductivity fluid, only the first space is filled with the fluid, providing sufficient heat dissipation with minimal fluid volume and thus minimal weight increase.
4Temperature
If the case is filled with high thermal conductivity fluid to maximize heat dissipation, then heat dissipation is improved, but the charger becomes difficult to manufacture due to narrow separation spaces
Solution Approach 1:
The case is segmented into a first space and a second space separated by a partition wall. The partition wall creates a defined boundary that facilitates fluid injection into the first space without requiring access through narrow gaps between components and the case.
Solution Approach 2:
The partition wall acts as an intermediary structure that separates the fluid injection space from other components, providing a clear pathway for fluid injection and simplifying the manufacturing process.
5Temperature
If high thermal conductivity fluid is injected before component assembly to ensure even distribution, then heat dissipation uniformity is improved, but electrical terminals and components become stained with fluid causing poor contact
Solution Approach 1:
The case is divided into a first space for fluid injection and a second space for components and terminals. The partition wall separating these spaces prevents fluid from contacting electrical components, ensuring both uniform heat dissipation and reliable electrical contact.
Solution Approach 2:
The partition wall serves as a protective barrier that mediates between the fluid injection process and the electrical components, allowing fluid to be injected into the first space without contaminating the second space where sensitive electrical components are located.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables efficient heat dissipation in the electric appliance, maintains a reduced size and weight, and prevents excessive temperature exposure, thereby enhancing the longevity and performance of the components.
Implementation Method 1
a potting pattern including a resin material and formed in the first space
Implementation Method 2
a partition wall disposed between the first space and the second space in the case to separate the first space and the second space from each other
Data Source
AI summary
Provided are an electric appliance and a method of manufacturing the same, the electric appliance having a smaller size and a reduced overall weight by preventing a fluid from flowing into a space unrelated to a heating component in a state where the fluid fills its case. The electric appliance includes: a case including a first space and a second space communicated to each other; a first component disposed in the first space; a second component disposed in the second space; a connection portion electrically connecting the first component and the second component to each other; and a potting pattern including a resin material and formed in the first space.