Cooling Wall Insulation Assembly for Creepage Distance Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electronic systems in electric vehicles face challenges in managing creepage and clearance distances due to increasing voltage requirements, leading to potential electrical interference, insulation faults, and mechanical space constraints, which can result in malfunctions, fires, or electrocution.
Innovation Solution
An electronic system with a housing containing an electronic module and a cooling device, utilizing a means for managing leakage and clearance distances through at least two insulating elements of different rigidities, ensuring adequate insulation while maintaining a compact size, comprising a first insulating element compressed between the heat exchange wall and the electronic module, and a second insulating element extending perpendicularly to lengthen the distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If large leakage and clearance distances are applied to ensure electrical insulation, then electrical safety is improved, but mechanical space requirements increase
Solution Approach 1:
The patent introduces a vertical dimension by positioning the electronic module on a protrusion of the heat exchange wall, thereby separating conductive components in the vertical direction rather than only in the horizontal plane. This allows adequate creepage and clearance distances to be maintained while minimizing the overall footprint of the electronic system.
Solution Approach 2:
The patent employs insulating elements as intermediaries between conductive components. These insulating elements provide the necessary creepage and clearance distances while allowing the components to be positioned closer together in the horizontal plane, thus resolving the contradiction between electrical insulation requirements and mechanical space constraints.
2Volume of moving object
If the electronic module is positioned close to the heat exchange wall for compact design, then device size is reduced, but electrical interference and insulation faults increase
Solution Approach 1:
The patent utilizes the vertical dimension by positioning the electronic module on a protrusion, creating separation between conductive components in the vertical direction. This allows the module to be compact in the horizontal plane while maintaining adequate insulation distances through vertical spacing.
Solution Approach 2:
Insulating elements are introduced as intermediaries between the electronic module and the heat exchange wall, providing necessary electrical insulation while allowing close proximity for thermal management. These intermediaries enable both compact design and adequate insulation.
3Temperature
If the heat exchange wall is made of thermally conductive material for effective cooling, then heat dissipation is improved, but electrical conductivity creates insulation issues
Solution Approach 1:
The patent segments the heat exchange wall structure by introducing a protrusion that creates a separation between the thermally conductive base and the conductive pins. This segmentation allows the base to remain thermally conductive for effective heat dissipation while the protrusion provides electrical insulation pathways.
Solution Approach 2:
Insulating elements serve as intermediaries between the thermally conductive heat exchange wall and the conductive pins, allowing thermal conduction to continue while providing the necessary electrical insulation. This resolves the contradiction between thermal conductivity requirements and electrical insulation needs.
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 effectively extends creepage and clearance distances, preventing electrical interference and condensation-related issues, ensuring compliance with industry standards and enhancing the reliability and safety of the electronic system.
Implementation Method 1
a protrusion thermally connected to the electronic module via a thermal interface material
Implementation Method 2
a cooling device which comprises a fluid circulation conduit delimited at least by a heat exchange wall
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The invention relates to an electronic system (1) comprising an electronic module (6) and a cooling device (10) comprising a fluid circulation conduit (32) delimited by a heat exchange wall (12) against which the module (6) is brought, the wall (12) having a base (14) and an extension (16) thermally connected to the module (6) and allowing it to be positioned at a distance from the base (14) in a vertical direction (V), the electronic system being provided with a means (24) for managing the leakage and clearance distances between at least one connection pin (22) of the module and the wall (12), the management means comprising an insulation assembly composed of at least two insulating means of different rigidities, among which a first insulating means (26) is compressed between the base (14) and the module (6), and a second insulating means (28) extends perpendicularly to the vertical direction (V).