Cold Sprayed Circuit Arrangement for Vibration-Resistant Motor Vehicle Connections
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing circuit arrangements in motor vehicles are susceptible to breakage due to vibrations, particularly in electrical connections with high inductance and current-carrying coils, which can lead to detachment or breakage and heat buildup.
Innovation Solution
A circuit arrangement featuring a heat sink with a layer arrangement formed by cold gas spraying of insulating and conductive materials, where the insulating layer is electrically insulating and the conductive layer is arranged on the side facing away from the heat sink, reinforced by a magnetic layer structure to enhance stability and heat dissipation, and optionally includes thermal decoupling features and a cooling channel for effective cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional electrical connections with high inductance coils are used, then high current carrying capability is achieved, but the connections become susceptible to vibration-induced breakage and detachment
Solution Approach 1:
The patent replaces traditional mechanical soldered connections with a cold gas spraying process that creates metallurgical bonds. The electrical connection path is formed by spraying conductive material (e.g., copper or silver powder) onto the heat sink surface, creating a vibration-resistant connection through material deposition rather than mechanical attachment.
Solution Approach 2:
The patent uses composite material structures where a heat sink is coated with alternating layers of insulating material (e.g., ceramic powder) and conductive material (e.g., metal powder). This creates a composite structure that provides both electrical connection and mechanical stability against vibrations.
2Use of energy by moving object
If large ferrite coils with many windings are used for high inductance, then high current carrying capability is achieved, but the component becomes heavy and susceptible to oscillation and swing
Solution Approach 1:
The patent replaces traditional bulky ferrite coils with a planar electrical connection path formed by cold gas spraying conductive material directly onto the heat sink. This creates an integrated inductor structure that provides the necessary inductance without the weight and vibration susceptibility of traditional wound coils.
Solution Approach 2:
The patent transitions from three-dimensional wound coils to a two-dimensional planar connection path on the heat sink surface. The electrical connection path extends across the heat sink surface, providing inductance through its geometric configuration rather than through tight windings, thereby reducing mass.
3Power
If large ferrite coils with high continuous current are used, then high power capability is achieved, but heat buildup (hotspot) occurs in the component
Solution Approach 1:
The patent merges the electrical connection path with the heat sink structure by directly spraying conductive material onto the heat sink surface. This integration creates direct thermal coupling between the current-carrying path and the heat dissipation structure, eliminating hotspots by ensuring heat generated in the connection path is immediately conducted away.
Solution Approach 2:
The heat sink serves multiple functions: it provides the substrate for the electrical connection path, acts as the primary heat dissipation structure, and provides mechanical support. The electrical connection path and heat dissipation function are combined in a single integrated structure rather than separate components.
4Reliability
If soldered connections are used for electrical connections, then electrical connectivity is achieved, but the connections become vulnerable to detachment under vibration
Solution Approach 1:
The patent replaces mechanical soldered connections with a cold gas spraying process that creates direct metallurgical bonds between the conductive material and the heat sink surface. This deposition-based connection method produces a more robust bond that is resistant to vibration-induced detachment.
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
The solution provides a vibration-proof electrical connection that effectively dissipates heat and maintains stability under high current conditions, preventing natural oscillations and ensuring reliable operation in vibrating environments.
Implementation Method 1
The layer arrangement is formed by cold gas spraying of a respective material of one or some or each of the layers of the layer arrangement
Implementation Method 2
The conductor layer is arranged on a side of the insulating layer facing away from the heat sink
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The invention relates to a circuit arrangement (15) comprising a heat sink (17) and a layer assembly (20) which is disposed on a surface (21) of the heat sink (17) and which includes a first electrically insulating insulation layer (28) on the heat sink (17) as well as an electrically conductive conductor layer (29) on the side of the insulation layer (28) facing away from the heat sink (17), the layer assembly (20) forming an electric connection path (24) between two electric terminal regions (22, 23). According to the invention, the layer assembly is formed by cold spraying a material for at least one of the layers (28, 29) of the layer assembly (20), i.e. said at least one layer (28, 29) has properties that are imparted to the material by the cold spraying process.