Insulating Plate Recess Design for Terminal Block Heat Transfer
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Solution Overview
Problem
Existing insulating members in terminal blocks form air layers with low thermal conductivity when separated from molds, reducing heat transfer efficiency from conductors to heat sinks.
Innovation Solution
The insulating plate features nut accommodating recesses with a pressing portion on the surrounding wall, allowing for efficient separation from the mold without indenting the base plate, ensuring close contact between nuts and the heat sink for improved heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If ejector pins are used to separate the insulating member from the mold, then the insulating member can be removed from the mold, but indents are formed on the bottom surface of the recesses creating air layers that reduce heat transfer efficiency
Solution Approach 1:
A release agent is applied to the mold pins before molding to prevent the resin from bonding directly to the mold surface. This intermediary substance allows the insulating member to be easily separated from the mold without requiring ejector pins that would create indents on the bottom surface, thus maintaining surface flatness and heat transfer efficiency
2Adaptability or versatility
If the insulating member is designed with recesses for nuts, then the nuts can be accommodated and heat transferred, but the resin contracts when separated from the mold making separation difficult
Solution Approach 1:
The release agent serves as an intermediary between the mold pins and the resin material, preventing direct bonding while allowing the recesses to maintain their shape for proper nut accommodation. This enables both functional requirements to be met simultaneously
3Ease of manufacture
If air layers are formed between the nuts and the heat sink, then the insulating member can be easily separated from the mold, but heat transfer efficiency is reduced due to low thermal conductivity of air
Solution Approach 1:
By using a release agent instead of ejector pins, the bottom surface of the recess remains flat and free of indents, preventing the formation of air layers between the nuts and the heat sink. This maintains direct contact for efficient heat transfer while still enabling easy mold separation through the release agent
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 enhances heat radiation performance by preventing air layers with low thermal conductivity, allowing for more efficient heat transfer from nuts to the heat sink, thereby improving the thermal efficiency of the terminal block.
Implementation Method 1
Heat transferred from the conductors to the nuts is transferred to the heat sink via the insulating member and is radiated from the heat sink in the terminal block
Implementation Method 2
Heat transferred from the conductors to the nuts is transferred to the heat sink via the insulating member and is radiated from the heat sink in the terminal block
Data Source
AI summary
An insulating plate (20) made of synthetic resin for transferring heat transferred from conductors to nuts (10) to a heat sink (40) is provided with nut accommodating recesses (21) for accommodating the nuts (10). Each nut accommodating recess (21) includes a bottom plate (22) to be sandwiched between the nuts (10) and the heat sink (40) and a surrounding wall (23) vertically extending from the bottom plate (22) to surround the side surface of the nut (10). The surrounding walls (23) are provided with first and second pressing surfaces (28, 29) to be pressed by ejector pins (83).