Power Converter Heat Sink Insulation for Compact Grounded Housing
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Solution Overview
Problem
Conventional power conversion units require a significant gap for insulation between the heat sink and the frame ground, leading to increased size and space requirements due to the thickness of insulating bushings, which is not ideal for compact designs.
Innovation Solution
A power conversion unit design featuring a heat sink with a flat plate base and heat dissipation fin, where electrical insulation is achieved using a first insulating member with a flat plate shape and bent portions, allowing for reduced thickness and compact size while maintaining insulation between the heat sink and housing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulating bushing with sufficient thickness is used to achieve electrical insulation between the heat sink and the frame ground, then electrical insulation is ensured, but the power conversion unit increases in size and requires more space
Solution Approach 1:
The insulating member transitions from a conventional thick linear structure to a multi-dimensional configuration with a base portion and bent portions that extend in multiple directions. This dimensional change allows the insulating member to provide sufficient electrical insulation distance without increasing the overall vertical height of the power conversion unit, effectively resolving the contradiction between insulation reliability and compact size.
Solution Approach 2:
The bent portions of the insulating member are positioned to fit within or alongside other structural elements of the heat sink assembly, allowing the insulating member to be nested within the existing structure rather than adding external bulk. This nesting approach maintains insulation effectiveness while minimizing the overall volume occupied by the insulation system.
2Reliability
If a thick insulating bushing is arranged between the heat sink and the frame ground, then electrical insulation distance is achieved, but the vertical height of the power conversion unit increases
Solution Approach 1:
The insulating member uses bent portions that extend horizontally and diagonally rather than purely vertically, redistributing the insulation distance across multiple spatial dimensions. This allows the required electrical insulation distance to be achieved while keeping the vertical height projection minimal, directly addressing the contradiction between insulation distance and vertical dimension.
Solution Approach 2:
The bent portions of the insulating member introduce curved geometries that efficiently utilize diagonal space, allowing the insulating path to achieve sufficient length for electrical insulation without projecting significantly in the vertical direction. The curved configuration optimizes the insulation path length while minimizing the vertical footprint.
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 design enables a more compact power conversion unit size while ensuring electrical insulation between the heat sink and housing, reducing the vertical height and space requirements.
Implementation Method 1
a first insulating member that electrically insulates the heat sink and the housing from each other
Implementation Method 2
a heat dissipation fin
Implementation Method 3
heat dissipation fin
Data Source
AI summary
A heat sink includes a base having a flat plate shape and a heat dissipation fin. A housing accommodates the heat dissipation fin and is connected to ground. The base includes a first surface on which a semiconductor module is mounted, and a second surface opposite the first surface and to which the heat dissipation fin is fixed. The housing includes a flange supporting the second surface of the base. The power conversion unit further includes a first insulating member that electrically insulates the heat sink and the housing from each other. The first insulating member includes a base portion and a first bent portion. The base portion has a flat plate shape and is provided between the second surface of the base and the flange. The first bent portion is bent perpendicular to the base portion and is in surface contact with a side surface of the base.