Interlaced Fin Thermally Conductive Insulator Design
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Solution Overview
Problem
Existing thermally conductive insulators face challenges in balancing electrical insulation and thermal conductivity, particularly in electrical components where materials with both properties are scarce, leading to inefficient heat dissipation and mechanical stability issues.
Innovation Solution
A thermally conductive insulator design featuring interlaced fins on two parts with an insulating layer in between, allowing for enhanced heat transfer and mechanical stability, which can incorporate electrical functional components and various materials for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a planar connection with poor thermally conductive components is used, then electrical insulation is maintained, but thermal conductivity deteriorates
Solution Approach 1:
The patent transitions from planar (2D) contact to a three-dimensional (3D) interlaced fin structure. The fins extend perpendicular to the contact surfaces, creating multiple heat transfer pathways through the insulator thickness. This dimensional change increases the effective thermal conduction area without compromising electrical insulation, as the insulating layer surrounds the fins throughout their length.
Solution Approach 2:
The insulator employs a composite structure combining thermally conductive materials (for the fins) with electrically insulating materials (for the matrix and insulating layer). This allows the fins to efficiently conduct heat while the insulating material maintains electrical isolation between conductors at different potentials, resolving the contradiction between thermal and electrical properties.
2Loss of energy
If ceramics are used for good thermal conductivity and electrical insulation, then thermal and electrical properties are improved, but mechanical stability deteriorates due to brittleness
Solution Approach 1:
The patent uses a composite material system where thermally conductive fins (which could be ceramic or metal) are embedded in a mechanically robust insulating matrix material. This composite approach allows the fins to provide thermal conduction while the matrix provides mechanical strength and fracture resistance, overcoming the brittleness limitation of pure ceramic solutions.
Solution Approach 2:
Different regions of the insulator have different material properties optimized for their specific functions: the fins are made of thermally conductive material for heat transfer, while the matrix and insulating layer use mechanically strong, electrically insulating materials. This local differentiation allows each component to excel at its primary function without compromising overall performance.
3Strength
If plastics are used for mechanical stability and ease of manufacture, then mechanical properties are improved, but thermal conductivity deteriorates
Solution Approach 1:
The patent creates a composite structure where plastics or polymer-based insulating materials form the matrix and insulating layer, providing mechanical stability and ease of manufacture. Thermally conductive fins (made of metal, ceramic, or thermally conductive polymer composites) are embedded within this plastic matrix, providing the necessary thermal conduction pathways. The composite structure combines the mechanical advantages of plastics with the thermal conductivity of the fin materials.
4Volume of moving object
If the insulating layer is made thin for compact design, then space is reduced, but electrical insulation capability deteriorates
Solution Approach 1:
The patent compensates for the reduced insulating layer thickness by introducing three-dimensional fin structures that extend through the insulator. These fins create multiple distributed contact points and heat transfer pathways, allowing the thermal function to be maintained even with a thinner insulating layer. The interlaced fin configuration ensures adequate electrical clearance while preserving thermal conduction efficiency.
Solution Approach 2:
The insulator is segmented into multiple functional components: thin insulating layers for electrical isolation, thermally conductive fins for heat transfer, and a structurally supportive matrix. This segmentation allows each component to be optimized independently - the insulating layer can be made thin for compactness while the fin structure compensates for thermal conduction, and the matrix provides mechanical support.
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 significantly improves thermal conductivity and mechanical stability, enabling higher power densities and reduced material usage while maintaining electrical insulation, even with thin layers and high voltages, and eliminates the need for additional fastening components.
Implementation Method 1
an insulating layer is arranged between the first part and the second part at least in the region of the fins
Implementation Method 2
thermally conductive insulator... significantly improves thermal conductivity... heat transfer is distributed on this surface
Implementation Method 3
the first fins and the second fins are arranged in such a way that they mesh with one another... a significantly larger surface to be used for a heat transfer
Data Source
AI summary
A thermally conductive insulator includes a first part having first fins arranged on a surface of the first part, and a second part having second fins arranged on a surface of the second part. The first fins and the second fins are arranged in such a way that they mesh with one another. Arranged between the first and second parts in a region of the first and second fins is an insulating layer.