Bus Bar Assembly With Compression-Limited Thermal Interface
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Solution Overview
Problem
In circuit assemblies with heat generation components, excessive compression of heat conductive members due to manufacturing and assembly tolerances can lead to damage from repulsive forces, compromising heat dissipation efficiency.
Innovation Solution
A circuit assembly design where bus bars press an elastic heat conductive member against a defined positioning structure on an insulating base member, controlling the compression ratio to prevent excessive force and ensure stable heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the heat conductive member is compressed to enhance heat conductive efficiency, then heat dissipation efficiency is improved, but excessive compression due to manufacturing and assembly tolerances causes large repulsive force that may damage members
Solution Approach 1:
The patent introduces a recess structure in the base member that beforehand limits the compression amount of the heat conductive member. The bus bar positioning portion is formed at a predetermined depth from the mounting surface, creating a mechanical stop that prevents excessive compression before it can cause damage. This cushioning effect ensures that the heat conductive member is compressed enough to achieve good thermal contact while preventing the repulsive force from becoming excessively large and damaging to the heat generation component or other members.
2Ease of manufacture
If manufacturing and assembly tolerances are not controlled, then ease of manufacture is improved, but heat conductive member compression becomes excessive due to accumulated tolerances
Solution Approach 1:
The recess structure is preliminarily formed in the base member during manufacturing, creating a built-in positioning and limiting mechanism. The bus bar positioning portion protruding from the mounting surface by a predetermined depth is created in advance, so that when assembly occurs, the compression of the heat conductive member is automatically limited without requiring tight control of manufacturing and assembly tolerances. This preliminary action eliminates the need for precise tolerance control while preventing excessive compression.
3Adaptability or versatility
If the heat conductive member is made elastic to accommodate compression, then adaptability to tolerance variations is improved, but repulsive force increases when compressed excessively
Solution Approach 1:
The patent applies local quality by creating a specific recess structure in the base member that locally controls the compression environment of the heat conductive member. The bus bar positioning portion creates a localized boundary condition that limits compression to a safe amount. This allows the heat conductive member to be elastic and adaptable to some compression variations while preventing it from being compressed beyond the point where excessive repulsive force is generated. The local recess structure modifies the global compression behavior to achieve both adaptability and force control.
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 design effectively prevents damage from excessive repulsive forces and maintains excellent heat dissipation properties by ensuring uniform and controlled compression of the heat conductive member.
Implementation Method 1
an elastic heat conductive member that is in thermal contact with the bus bars
Implementation Method 2
the bus bars press the heat conductive member in a mounting direction in which the bus bars are mounted on the base member
Implementation Method 3
When the heat conductive member is compressed excessively, a large stress acts between members due to the repulsive force of the heat conductive member
Data Source
AI summary
The present disclosure provides a circuit assembly that has a novel structure, with which it is possible to prevent the occurrence of a problem caused by an excessive repulsive force of a heat conductive member by controlling the repulsive force of the heat conductive member. A circuit assembly includes: a heat generation component; bus bars that are connected to connecting portions of the heat generation component; an insulating base member that holds the heat generation component and the bus bars; and an elastic heat conductive member that is in thermal contact with the bus bars. The bus bars press the heat conductive member in a mounting direction in which the bus bars are mounted on the base member. As a result of the bus bars abutting against bus bar positioning portions provided on the base member, the positions of the bus bars in the mounting direction are defined.