Electrical Assembly Insulation and Cooling via Crushed Rivet Studs
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Solution Overview
Problem
In the field of electric and hybrid vehicles, there is a need for electrical assemblies without a chassis or casing that can maintain electrical and mechanical components, such as a connection capacitor and a heat dissipation device, which can be handled independently and later inserted into a frame to form electrical equipment like an inverter, while ensuring proper insulation and heat dissipation.
Innovation Solution
An electrical assembly comprising a support with a cooling device, a separator element for electrical insulation between the capacitor and the cooling device, and rivet studs from the separator element that crush to form connecting zones, allowing the assembly to be reversed and inserted into a chassis, with additional snaps for integral assembly and insulation elements to manage leakage currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the electrical assembly is designed without a chassis or casing to enable independent handling and later insertion into a frame, then the adaptability and ease of assembly process compatibility are improved, but the structural stability and mechanical support are worsened
Solution Approach 1:
The electrical assembly is divided into a modular structure where the support (without full chassis) holds the capacitor and cooling device, and this modular unit is designed to be inserted into a frame later. This segmentation allows independent handling of the modular unit while maintaining structural integrity through the support's optimized design.
Solution Approach 2:
The electrical assembly is designed as a nested structure where the support with mounted components fits into a frame, creating a hierarchical assembly. The support acts as an inner structure that provides initial stability, while the outer frame provides final structural support, enabling both independent handling and overall stability.
2Ease of manufacture
If the separator element uses rivet studs that crush to form connecting zones, then the ease of manufacture and assembly are improved, but the manufacturing precision and connection reliability are worsened
Solution Approach 1:
The rivet studs are pre-formed on the separator element with predetermined crushing characteristics. The crushing action is designed to occur at a specific stage of assembly, creating connecting zones with controlled deformation. This preliminary preparation of the rivet studs ensures that the crushing process achieves both ease of assembly and acceptable connection reliability.
Solution Approach 2:
The material properties of the rivet studs are specifically selected to enable controlled crushing under assembly pressure. By changing the material parameters (ductility, strength) of the rivet studs, the design achieves a balance between ease of formation (crushing) and connection reliability, allowing the studs to deform and form connecting zones without compromising structural integrity.
3Device complexity
If the cooling device is directly mounted on the support without additional insulation, then the device complexity is reduced, but the electrical insulation and safety are worsened
Solution Approach 1:
The separator element is designed to perform multiple functions simultaneously: it provides electrical insulation between the capacitor and cooling device, serves as a mechanical support structure, and incorporates rivet studs for assembly. This multi-functionality reduces the need for separate insulation components, maintaining low device complexity while ensuring adequate electrical insulation through the separator element's material properties and geometric design.
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 enables the formation of an integral electrical assembly capable of reversal, ensuring effective heat dissipation and electrical insulation, facilitating the insertion into a chassis while maintaining the integrity of the heat dissipation cushion and thermal properties over time.
Implementation Method 1
a support, comprising a cooling device configured to dissipate heat emitted by a link capacitor
Implementation Method 2
a cooling device configured to dissipate heat emitted by a link capacitor
Implementation Method 3
a separator element, arranged between the cooling device and the link capacitor, configured to provide electrical insulation between the link capacitor and the cooling device
Implementation Method 4
the said studs being configured to crush under the pressure, during assembling the electrical assembly, so as to form connecting zones between the separator element and the connecting capacitor
Data Source
Figure 1~2
Figure 3
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AI summary
The present invention relates to an electrical assembly comprising: - a support, including a cooling device configured to dissipate heat emitted by a capacitor; - a separator element (20) disposed between the cooling device and the connecting capacitor configured to provide electrical insulation between the capacitor and the cooling device; said capacitor, comprising at least one capacitive coil and at least one electrical connection bar welded to said at least one capacitive coil, said at least one electrical connection bar being at least partially disposed on the side of the separator element (20); the electrical assembly comprising first retaining elements for the separator element (20) on said support, said separator element (20) further incorporating second retaining elements adapted to ensure the retention of the capacitor on the support.