Electrical Connection Assembly Thermal Management
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Solution Overview
Problem
Existing inverter connection assemblies are complex, costly, and lack environmental sealing, electromagnetic shielding, and current sensing capabilities, making them inefficient and prone to damaging internal components during installation.
Innovation Solution
A compact electrical connection assembly featuring a metal housing with integrated cooling passages, a copper socket for cable connection, a direct heat sink for thermal management, and a cylindrical current sensor, all within a sealed and shielded design that simplifies installation and reduces component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate components and compartments are used to achieve environmental sealing, electromagnetic shielding, and current sensing, then reliability is improved, but device complexity increases
Solution Approach 1:
The patent combines multiple separate components (housing, cover, heat sink, current sensor, cable connector) into an integrated connection assembly where the cover serves dual purposes as both a seal and a mounting structure for the current sensor and heat sink, reducing the number of separate components while maintaining all required functions
Solution Approach 2:
The cover is designed to perform multiple functions: providing environmental sealing, mounting the current sensor, supporting the heat sink, and protecting internal components. This multi-functionality reduces the overall component count while maintaining reliability
2Temperature
If a direct heat sink connection is implemented, then thermal management is improved, but manufacturing precision requirements increase
Solution Approach 1:
A thermal interface material is introduced as an intermediary between the heat sink and the power module socket to ensure optimal thermal contact. This mediator compensates for minor surface irregularities and achieves effective heat transfer without requiring extremely tight manufacturing tolerances
3Productivity
If a compact design is used, then productivity is improved, but ease of operation decreases
Solution Approach 1:
The connection assembly is designed as a pre-assembled module with segmented components (cable connector, heat sink, current sensor) that are integrated during manufacturing but installed as a single unit, combining compact design with ease of installation
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 assembly provides a cost-effective, compact, and environmentally sealed solution that protects internal components, integrates current sensing, and enhances thermal management, reducing assembly time and size while ensuring electromagnetic shielding.
Implementation Method 1
A heat sink member conducts heat directly from the socket to the metal housing
Implementation Method 2
An electrically insulating thermally conducting pad is positioned between the housing and a second end of the heat sink member
Data Source
AI summary
An electrical connection assembly includes a metal housing and an electrical module having a plurality of electrical components mounted on a component base. The base is supported on the housing. A socket conducts electrical current from a pin of a cable to the electrical components. A heat sink member conducts heat directly from the socket to the metal housing. An electrically insulating thermally conducting pad is positioned between the housing and an end of the heat sink member. A current sensor has a cylindrical body which surrounds a portion of the socket.