Inverter Power Module Base for Uniform Cooling Assembly
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Solution Overview
Problem
Existing systems for assembling, testing, and securing power module assemblies in electric vehicle inverters face challenges such as improper cooling system assembly leading to failure, complex assembly processes, and high scrap rates due to inadequate testing and force distribution on heatsinks.
Innovation Solution
A base system for power module assemblies is introduced, featuring a body with rim, pin slots, and engagement slots, contact terminals, and electrical connectors. This base system provides a unified platform for electrical connections between power modules and a substrate, while also accommodating heatsinks and ensuring even force distribution for improved cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cooling systems are used with separate assembly processes for heatsinks and power modules, then the cooling function is provided, but the assembly complexity increases and the risk of improper assembly leading to failure increases
Solution Approach 1:
The patent combines the heatsink assembly and power module assembly into a single integrated base structure. The base includes a heatsink portion with cooling channels and a power module portion with electrical connections, allowing both cooling and electrical functions to be assembled together in one operation, thereby reducing assembly complexity and improving reliability by eliminating separate assembly steps that could lead to improper installation
Solution Approach 2:
The base structure serves multiple functions simultaneously: it provides thermal management through integrated cooling channels, electrical connections through contact terminals and electrical connectors, and mechanical support for power modules. This multi-functional design reduces the number of separate components and assembly processes needed, addressing both the reliability and complexity concerns
2Reliability
If power modules are securely fastened to substrate, then electrical connection is provided, but the assembly process becomes more complex requiring multiple fastening operations
Solution Approach 1:
The base integrates the fastening structure into its overall design, where the power module portion of the base directly receives and secures power modules through built-in engagement features. The fasteners are received within the base structure itself, combining the support and fastening functions into a single integrated component rather than requiring separate fastening operations
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 base system facilitates efficient assembly, testing, and securement of power module assemblies, reducing scrap rates and improving thermal performance by ensuring uniform force distribution and even thermal interface material application between heatsinks and power modules.
Implementation Method 1
Heatsinks may provide effective means of dissipating heat by thermally conducting heat into a fluid medium
Implementation Method 2
often via a utilization of Thermal Interface Material (TIM)
Data Source
AI summary
A base for an electrical component includes: a body, the body defining: a rim, pin slots, and first engagement slots; contact terminals; and electrical connectors, each of the electrical connectors being positioned within a respective pin slot and including a pin terminal positioned on a first surface of the body; wherein the base is configured to provide an electrical connection between one or more power modules and a substrate.