Insulated Case Structure for Compact Heat-Dissipating Electronics

Solution Overview

Problem

Existing electronic components that generate heat face a challenge in achieving both reduced size and high heat dissipation performance, as traditional metal cases provide good heat dissipation but require distance for electrical insulation, while resin cases ensure insulation but lack heat dissipation efficiency.

Innovation Solution

An electronic component design featuring a case with an electrically insulating body and thermally conductive bottom, filled with a thermosetting resin to reduce size while maintaining effective heat dissipation, where the bottom is in contact with a heat dissipator for enhanced thermal management.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If the case is made of metal to achieve high heat dissipation performance, then heat dissipation performance is improved, but the distance between the case and the heat generator must be increased to ensure electrical insulation

Engineering Contradiction:

Improveheat dissipation performanceVSAvoiddistance between case and heat generator

Core Design Contradiction:

TemperatureVSLength of stationary object

Solution Approach 1:

The case is constructed with different materials for different parts: the body is made of electrically insulating material while the bottom is made of thermally conductive material. This allows the bottom to be in direct contact with the heat generator for efficient heat dissipation without requiring electrical insulation, thus resolving the contradiction between heat dissipation performance and electrical insulation distance

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The case uses a composite structure combining electrically insulating material for the body and thermally conductive material for the bottom. This composite approach enables simultaneous achievement of electrical insulation (allowing reduced distance) and thermal conduction (improving heat dissipation), directly resolving the technical contradiction

Inventive Principle:

Principle #40Composite materials

2Reliability

If the case is made of resin composition to ensure electrical insulation between the case and the heat generator, then electrical insulation is improved, but heat dissipation performance deteriorates

Engineering Contradiction:

Improveelectrical insulationVSAvoidheat dissipation performance

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The case is constructed with different materials for different parts: the body is made of electrically insulating material while the bottom is made of thermally conductive material. This allows the bottom to be in direct contact with the heat generator for efficient heat dissipation without requiring electrical insulation, thus resolving the contradiction between heat dissipation performance and electrical insulation distance

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The case uses a composite structure combining electrically insulating material for the body and thermally conductive material for the bottom. This composite approach enables simultaneous achievement of electrical insulation (allowing reduced distance) and thermal conduction (improving heat dissipation), directly resolving the technical contradiction

Inventive Principle:

Principle #40Composite materials

3Volume of stationary object

If the distance between the case and the heat generator is reduced to achieve size reduction, then the size of the electronic component is reduced, but electrical insulation between the case and the heat generator becomes compromised

Engineering Contradiction:

Improvesize of electronic componentVSAvoidelectrical insulation

Core Design Contradiction:

Volume of stationary objectVSReliability

Solution Approach 1:

The case is constructed with different materials for different parts: the body is made of electrically insulating material while the bottom is made of thermally conductive material. This allows the bottom to be in direct contact with the heat generator for efficient heat dissipation without requiring electrical insulation, thus resolving the contradiction between heat dissipation performance and electrical insulation distance

Inventive Principle:

Principle #3Local quality

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 achieves reduced size with improved heat dissipation performance by ensuring electrical insulation and efficient thermal conductivity, eliminating the need for additional insulating materials and reducing component count.

Implementation Method 1

the bottom is electrically insulating and thermally conductive... the bottom contributes to effective heat dissipation... the bottom is in contact with a component such as a housing or heat dissipator which exhibits a high heat dissipation effect

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20240177913A1Electronic component

Publication Date: 2024.05.30 DIAMOND&ZEBRA ELECTRIC MFG CO LTD

AI summary

An electronic component includes: a heat generator; a case containing therein a part or whole of the heat generator, the case including a body and a bottom; and a filler filling a gap between the heat generator and the case. The body is electrically insulating, and the bottom is electrically insulating and thermally conductive. Preferably, the bottom includes a heat dissipation sheet. The bottom may be made of a ceramic. Preferably, the body includes a main portion and a flange portion located at an end of the main portion that faces the bottom, the flange portion projecting outward or inward from the main portion.