Electric Module Overmoulding Cavity for Heat Dissipation
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Solution Overview
Problem
Electrical modules with overmoulding are prone to overheating, which can lead to the insulating material catching fire due to heat diffusion, posing a risk to surrounding elements.
Innovation Solution
Incorporating a cavity in the upper face of the electrically insulating overmoulding to house part of the electrical connection element, allowing for easier breaking and reducing the temperature of the insulating material, thus minimizing the risk of fire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrical connection element is fully embedded in the insulating overmoulding, then the insulating coverage is improved, but the heat dissipation capability deteriorates causing fire risk
Solution Approach 1:
The insulating overmoulding is segmented into two distinct zones: a first zone that fully embeds the electrical connection element for insulation, and a second zone that exposes part of the connection element for heat dissipation. This segmentation allows the structure to simultaneously achieve both complete insulating coverage and effective heat dissipation, resolving the contradiction between insulation reliability and temperature control.
2Reliability
If the electrical connection element is fully embedded in the insulating overmoulding, then the insulation is improved, but the ease of breaking the connection element deteriorates
Solution Approach 1:
The overmoulding structure is divided into embedding and non-embedding zones, where the connection element is fully surrounded in the first zone for insulation but partially exposed in the second zone. This segmentation enables the connection element to be easily accessible for breaking or replacement operations while maintaining complete insulation where required, thus improving ease of operation without compromising insulation reliability.
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 lowers the temperature at which the electrical connection element breaks, limiting heat transfer to the electrical component and reducing the likelihood of the module catching fire during malfunctions.
Implementation Method 1
the heat diffuses into the electrical insulation so that the latter risks catching fire
Data Source
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AI summary
The invention relates to an electrical module comprising a first (3041) and a second (3042) electrical connection pieces each having a main plate (3061, 3062), a first electrical component (1121) mounted on an upper face of the main plate (3062) of the second electrical connection piece (3042), a first electrical linking element (3261) electrically connecting the upper face of the main plate (3061) of the first electrical connection piece (3041) to the upper face of the main plate (3062) of the second electrical connection piece (3042);and an electrical insulating overmolding (402), for example made of resin, covering said first electrical component (1121) and at least a portion of the upper face of the main plate (3061, 3062) of the first (3041) and second (3042) electrical connection pieces, said electrical module (110) being characterized in that the upper face of the electrical insulating overmolding (402) has a cavity (C) and in that at least a portion of the first electrical connection element (3261) is located in said cavity (C).