Integrated Diode Carrier Layout for Compact Overvoltage Protection
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Solution Overview
Problem
The installation of diode carrier arrangements in motor vehicle engine compartments is hindered by the need for reserved space and cabling, which limits the already constrained installation space.
Innovation Solution
A diode carrier arrangement featuring two diodes with integral connection contact pins, a rail arrangement of separate metal rails, and a moulded plastic enclosure that holds the metal plate sandwich-like between the rails, allowing for contactless electrical and thermal conductivity, enabling compact integration and reduced installation space requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a diode carrier arrangement is installed as an individual component in the engine compartment, then electrical protection function is provided, but installation space is reduced and cabling requirements increase
Solution Approach 1:
The patent combines the diode carrier arrangement with an electric machine (generator/alternator) by integrating it into the electric machine's housing or mounting structure. This merging eliminates the need for separate installation space in the engine compartment and reduces cabling requirements since the protection device is co-located with the electric machine it protects.
2Reliability
If a diode carrier arrangement is installed as an individual component in the engine compartment, then electrical protection function is provided, but cabling complexity increases
Solution Approach 1:
By integrating the diode carrier arrangement with the electric machine, the patent reduces cabling complexity. The protection device can share the electric machine's mounting structure and electrical connections, eliminating separate cabling runs from the engine compartment to the protection device.
3Reliability
If the metal plate directly touches the metal rails, then electrical conductivity is improved, but thermal management and electrical isolation are compromised
Solution Approach 1:
The patent introduces an intermediate substance (such as thermal paste, adhesive, or insulating material) between the metal plate and metal rails. This intermediary layer enables or enhances thermal conduction while maintaining appropriate electrical isolation, or allows controlled electrical contact while managing heat dissipation through the intermediate material's properties.
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 solution allows for the integration of diode carrier arrangements in electric machines like generators and alternators, saving installation space and facilitating efficient heat dissipation and electrical connectivity, while maintaining cost-effectiveness and ease of installation.
Implementation Method 1
between the diode body of the at least one diode and the first metal rail and/or the at least one metal plate, heat-conducting paste or heat-conducting adhesive is introduced, which wets both the diode body of the at least one diode as well as the first metal rail and/or the at least one metal plate
Implementation Method 2
the said first diode with its at least one connection contact pin is integrally connected to the at least one metal plate in an electrically conductive manner, in particular soldered or welded
Implementation Method 3
the said first diode with its at least one connection contact pin is integrally connected to the at least one metal plate in an electrically conductive manner, in particular soldered or welded
Implementation Method 4
by way of the enclosure clamped onto the first metal rail so that its connection contact and/or its diode body is contacted with the first metal rail electrically and in a thermally conductive manner
Data Source
Figure 1~3
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AI summary
The present invention relates to a diode carrier arrangement (1) comprising diodes (2a, 2b), a rail arrangement (3) comprising metal rails (4, 18), at least one metal plate (32) as well as an enclosure (38) for holding the rail arrangement (3) and/or the at least one metal plate (32). It is substantial that by way of the enclosure (38) and a first metal rail (4) of these metal rails (4, 18) a first diode receptacle (44) for receiving diodes (2a, 2b) and by way of the enclosure (38) and the at least one metal plate (32) a second diode receptacle (45) for receiving diodes (2a, 2b) is delimited. In the diode receptacles (44, 45) diodes (2a, 2b) are inserted and by way of the enclosure (38) clamped onto the first metal rail (4) and the at least one metal plate (32) respectively. The invention relates in particular to an overvoltage protection device (57) with a diode carrier arrangement (1), further in particular to a motor vehicle component having a diode carrier arrangement (1) or an overvoltage protection device (57) as well as further in particular to a manufacturing method for a diode carrier arrangement (1).