Modular Electrical Device with Dynamic Front-Rear Adjustment
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Solution Overview
Problem
The modular construction of electrical devices used in motor vehicles leads to large clearances and imperfect contact with cold plates, resulting in poor heat evacuation and stress on electronic components.
Innovation Solution
An electrical device comprising a main module fixed to a first support and an auxiliary module connected to a second support, with fasteners allowing movement in the front-rear direction to adjust positioning and improve contact with cold plates, reducing stress and enhancing thermal conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If modules are fixed rigidly to cold plate supports, then structural stability is improved, but manufacturing clearances cause imperfect contact and poor heat evacuation
Solution Approach 1:
The patent introduces a dynamic adjustment mechanism that allows the module to move relative to the cold plate support in the front-rear direction. This dynamic capability enables the module to compensate for manufacturing clearances and achieve perfect contact with the cold plate, resolving the contradiction between structural stability and positioning accuracy.
Solution Approach 2:
The patent changes the positional parameter of the module by allowing it to move along the front-rear axis. This parameter change enables the module to adjust its position to eliminate clearance gaps and achieve optimal thermal contact with the cold plate support.
2Strength
If modules are fixed rigidly to supports, then structural stability is improved, but thermal conduction efficiency deteriorates due to clearance gaps
Solution Approach 1:
The dynamic adjustment mechanism allows the module to move and achieve perfect thermal contact with the cold plate while maintaining structural stability through the fastening connection. This resolves the contradiction between structural strength and thermal conduction efficiency.
Solution Approach 2:
The fastening mechanism acts as an intermediary that maintains both structural connection and thermal contact. It allows the module to be firmly attached to the support while enabling positional adjustment to eliminate clearance gaps, thus ensuring both structural stability and efficient heat evacuation.
3Ease of manufacture
If modules are fixed rigidly, then assembly simplicity is improved, but stress on electronic components increases due to deformation constraints
Solution Approach 1:
The dynamic adjustment mechanism allows the module to self-adjust its position to match the support surface, eliminating the need for complex assembly procedures while simultaneously reducing stress on electronic components by preventing deformation constraints.
4Temperature
If clearances are reduced for better contact, then thermal conduction is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of reducing clearances through tighter manufacturing tolerances, the patent introduces a dynamic adjustment mechanism that allows the module to move and eliminate clearances after assembly. This approach maintains manufacturing simplicity while achieving perfect thermal contact.
Solution Approach 2:
The fastening mechanism is designed to perform the preliminary action of pulling the module into contact with the cold plate support. This preliminary action eliminates the need for precise clearance control during manufacturing, as the contact is achieved through the fastening process itself.
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 configuration allows for correct positioning of modules, reducing stress on the device and improving thermal conduction, thereby extending the device's lifetime and enhancing heat evacuation.
Implementation Method 1
the fastener(s) allowing movement of the auxiliary module relative to the main module, only in a front-rear direction, between a close position and a position far from the main module
Implementation Method 2
the contact of the modules with their respective supports is improved, so that better thermal conduction can be obtained when the supports are cold plate parts
Data Source
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AI summary
The electrical device (114) comprises: a main module (116); an auxiliary module (118) electrically connected to the main module (116); at least one fastener attaching the auxiliary module (118) to the main module (116) to prevent the auxiliary module (118) from detaching from the main module (116), the fastener(s) allowing the auxiliary module (118) to move relative to the main module (116), in a front-to-back (F-B) direction, between a position close to and a position far from the main module (116).