Heat Sink Frame Assembly for Modular Power Module Positioning
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Solution Overview
Problem
Conventional electrical devices often require complex and costly manufacturing processes, especially when incorporating heat sinks and power modules, which limits the variety of devices that can be produced efficiently.
Innovation Solution
The proposed solution involves an electrical device design that uses a metallic heat sink with a contact surface, a power module arranged on this surface with heat-conducting paste, and a plastic frame part that delimits the power module and is supported by the heat sink's bulge, allowing for efficient production of various devices from a construction kit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a frame part is added to accommodate the power module on the contact surface, then the adaptability to produce various electrical devices is improved, but the device complexity increases
Solution Approach 1:
The frame part serves multiple functions: it provides mechanical support for the power module, defines the accommodation space, and enables the construction kit to produce different electrical device configurations. This multi-functionality allows a single component to address various needs without increasing overall system complexity
Solution Approach 2:
The construction kit is divided into modular components (frame part, power module, contact surface) that can be independently manufactured and assembled. This segmentation allows for flexible combination of components to create different electrical devices while maintaining standardized production processes
2Device complexity
If the power module is placed directly on the contact surface without a frame part, then the device complexity is reduced, but the manufacturing precision and positioning accuracy deteriorate
Solution Approach 1:
The frame part acts as an intermediary element between the contact surface and the power module. It provides a standardized interface that ensures precise positioning and secure mounting of the power module, while maintaining manufacturability through conventional injection molding processes
3Reliability
If solder connections are used for electrical contacting, then the electrical connection reliability is improved, but the manufacturing time and production complexity increase
Solution Approach 1:
The patent replaces the traditional soldering process (thermal/chemical method) with a mechanical pressing connection system. The frame part and retaining plate provide mechanical pressure to ensure reliable electrical contact between the power module and circuit board, eliminating the need for soldering while maintaining connection reliability and enabling faster production
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 enables the cost-effective production of a wide variety of electrical devices using a minimal number of components, as the frame part allows smaller power modules to be used, reducing manufacturing costs and increasing flexibility.
Implementation Method 1
a heat-conducting paste interposed between the contact surface and the power module
Data Source
AI summary
In an electrical device and method for producing a first and second electrical device from a construction kit, the electrical device includes a heat sink having a contact surface, on which a power module is arranged. A frame part of the electrical device is arranged on the contact surface, the power module is accommodated in the frame part, and the frame part is delimited by a bulge of the heat sink protruding at the edge of the contact surface.