Voltage Converter Assembly With Heat Sink-Mounted Retention Spring
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Solution Overview
Problem
Existing voltage converters require indexing pins to hold a resilient element in place, which complicates the assembly process and can lead to detachment due to thermal adhesive deterioration over time.
Innovation Solution
The resilient elements are rigidly connected to the heat sink, eliminating the need for indexing pins and ensuring secure attachment of the power modules even under vibration and thermal stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If indexing pins are used to hold the resilient element in place, then the resilient element can be secured during assembly, but the device complexity increases and the risk of detachment due to thermal adhesive deterioration remains
Solution Approach 1:
The invention extracts and eliminates the indexing pins from the assembly, replacing them with a resilient element that is directly integrated into the cover structure. This removes the need for separate indexing components while maintaining the securing function through the resilient element's inherent elasticity and direct attachment to the heat sink.
Solution Approach 2:
The resilient element is merged with the cover as a single integrated component, where the cover itself serves as the mounting structure. This consolidation eliminates the need for separate indexing pins and reduces the number of parts, thereby simplifying the device while improving reliability through fewer potential failure points.
2Ease of manufacture
If thermal adhesive is used to attach the power module to the heat sink, then the assembly is simplified, but the attachment reliability deteriorates over time due to adhesive aging
Solution Approach 1:
The resilient element is pre-installed and rigidly connected to the heat sink before the power module is attached. This preliminary action ensures that the mechanical securing structure is in place beforehand, providing ongoing support and reducing dependence on the thermal adhesive's long-term bonding strength.
Solution Approach 2:
The resilient element acts as a cushioning mechanism that compensates for potential adhesive failure. By providing continuous elastic support, it beforehand prepares the assembly to withstand thermal cycling and vibration without complete detachment, even if the thermal adhesive deteriorates over time.
3Ease of operation
If the resilient element is not rigidly connected to the heat sink, then the assembly process is simpler, but the power module cannot be reliably held in place under vibration and thermal stress
Solution Approach 1:
The resilient element utilizes elastic deformation (curvature change) to provide securing force. By being rigidly connected at one end to the heat sink and extending to bear on the power module, it leverages its elastic properties to maintain reliable contact and retention under various operating conditions including vibration and thermal expansion.
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 stable and durable assembly that maintains the power modules in place, preventing detachment and ensuring effective heat dissipation, even as thermal adhesives age.
Implementation Method 1
at least one resilient element bearing on an upper face of the power module in order to hold the power module in place relative to the heat sink
Implementation Method 2
a heat sink having an upper face opposite a lower face of the power module in order to dissipate heat emitted by the power module
Implementation Method 3
after thermal adhesive inserted between the lower face of the power module and the upper face of the heat sink has been crosslinked by heating
Data Source
AI summary
The voltage converter (104) comprises:—a power module (110) comprising at least one controllable switch intended to switch in order to perform a voltage conversion;—a heat sink (206) having an upper face opposite a lower face of the power module (110) for dissipating heat emitted by the power module (110); and—at least one resilient element (308) bearing on an upper face of the power module (110) in order to hold the power module (110) in place relative to the heat sink (206).Each resilient element (308) is rigidly connected to the heat sink (206).