Controller Integrated Fuel Pump Module Air Gap Thermal Insulation
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Solution Overview
Problem
The existing fuel pump module designs face thermal deformation issues due to heat transfer from electronic components to the flange, which is made of materials with a lower temperature tolerance, leading to structural instability and potential component damage.
Innovation Solution
A controller integrated type fuel pump module is designed with a storage part that forms an air gap between the board and the flange, using a liquid resin to transfer heat to a heat dissipation part while keeping the flange isolated, thereby preventing excessive heat transfer and thermal deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If liquid resin is used to transfer heat from electronic components to heat sink, then heat dissipation performance is improved, but heat is transferred to the flange causing thermal deformation
Solution Approach 1:
The controller's inner space is divided into two separate spaces: a first space containing the electronic components and liquid resin for heat dissipation, and a second space containing the flange. The board edge acts as a partition wall between these spaces, preventing heat transfer from the liquid resin to the flange while maintaining effective heat dissipation from the electronic components.
Solution Approach 2:
The flange is extracted from the heat transfer path by placing it in a separate second space isolated from the liquid resin. This extraction prevents the flange from being exposed to the heat generated by electronic components, eliminating the thermal deformation problem while preserving the heat dissipation function.
2Productivity
If controller is integrated with flange to reduce components and assembly processes, then productivity is improved, but heat transfer to flange causes thermal deformation
Solution Approach 1:
The integrated controller-flange structure is segmented into two functional spaces: the first space for heat-generating electronic components with liquid resin cooling, and the second space for the flange. This spatial segmentation allows the controller to be integrated with the flange for manufacturing efficiency while preventing thermal interaction between the two components.
Solution Approach 2:
The board edge serves as an intermediary partition wall that separates the heat-generating first space from the flange-containing second space. This intermediary structure enables the integrated design to maintain both productivity benefits and thermal stability by blocking the heat transfer path.
3Device complexity
If liquid resin contacts both heat sink and flange to simplify structure, then device complexity is reduced, but thermal deformation of flange occurs
Solution Approach 1:
The structure is segmented into two distinct spaces separated by the board edge: the first space where liquid resin contacts the heat sink for heat dissipation, and the second space where the flange is isolated from the liquid resin. This segmentation maintains structural simplicity while preventing thermal deformation by blocking heat transfer to the flange.
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
This design effectively minimizes heat transfer to the flange, reducing the risk of thermal deformation and maintaining structural stability, and prevents component damage by using an air gap for insulation and efficient heat dissipation.
Implementation Method 1
forms an air gap between the board and the flange... minimizing heat transfer to the flange
Implementation Method 2
using a liquid resin to transfer heat to a heat dissipation part
Implementation Method 3
heat dissipation part while keeping the flange isolated, thereby preventing excessive heat transfer and thermal deformation
Data Source
AI summary
Provided are a controller integrated type fuel pump module for preventing thermal deformation of a flange and a manufacturing method thereof. An embodiment of the present invention is directed to providing a controller integrated type fuel pump module for preventing thermal deformation of a flange that minimizes heat transfer from a board to the flange through a thermal insulation effect by an air gap by improving a structure in a storage part of a controller to form the air gap between the board and the flange in the controller formed integrally with a fuel pump module, and a manufacturing method thereof.