Modular Plastic Housing With Monolithic Cooling Mount
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Solution Overview
Problem
Module housings made of thermosetting polymer with embedded cooling elements face bending tensions when attached to a heat sink, which can lead to cracking due to uneven pressure distribution, compromising thermal discharge efficiency.
Innovation Solution
A module housing with an embedded cooling element and a monolithic screw sleeve, where the screw sleeve is connected to the cooling element to form a single unit with a raised mounting surface, allowing for even pressure distribution and minimizing bending tensions, thereby enhancing thermal conductivity and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the cooling element is connected to the heat sink through separate screw sleeves, then the mechanical connection is established, but bending tensions occur in the plastic housing leading to cracking
Solution Approach 1:
The screw sleeve and cooling element are merged into a single monolithic element through integral connection during molding. This combines the mechanical fastening function and thermal conduction function into one component, eliminating the separate screw sleeve that caused bending tensions in the housing.
Solution Approach 2:
The monolithic element combines plastic (for housing compatibility) and metal (for thermal conduction and mechanical strength) in an integral structure. This composite approach allows the element to be firmly connected to the housing while providing efficient thermal discharge without creating stress concentrations.
2Temperature
If pressure is applied to the heat sink through screw sleeves, then thermal contact is improved, but uneven pressure distribution causes bending tensions
Solution Approach 1:
The pressure application is segmented through multiple collars at different positions on the monolithic element. Each collar applies pressure at a specific location, distributing the total load across multiple contact points rather than concentrating it at a single screw sleeve location, thereby achieving even pressure distribution.
Solution Approach 2:
Different regions of the monolithic element have different functions: the collar regions are optimized for mechanical pressure application, while the cooling element region is optimized for thermal conduction. This local differentiation allows pressure to be applied where needed without compromising thermal performance or creating bending tensions.
3Area of stationary object
If the cooling element has a fully embedded exposed planar surface, then thermal contact area is maximized, but the housing becomes more susceptible to bending tensions
Solution Approach 1:
The cooling element and screw sleeve are merged into a monolithic structure that provides both thermal contact area and mechanical stability. The integral connection distributes stresses throughout the combined structure, preventing the bending tensions that would occur with separate components.
Solution Approach 2:
The monolithic element uses composite construction to simultaneously achieve large thermal contact area and resistance to bending tensions. The metal portion provides thermal conductivity and structural rigidity, while the plastic portion ensures compatibility with the housing and distributes mechanical stresses.
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 solution effectively reduces bending tensions in the plastic housing, ensuring efficient thermal discharge and mechanical stability, with optimized heat dissipation through a larger mounting surface, reducing the need for extensive surface processing and preventing cracking.
Implementation Method 1
heat is conducted away from the cooling element to the support through at least the mounting surface
Implementation Method 2
pressure is applied to the support via the mounting surface of the at least one screw sleeve, resulting in an equal counterpressure
Data Source
AI summary
The invention relates to a module housing made of plastic, in particular a thermosetting polymer, with an embedded cooling element and at least one screw sleeve, which has a collar with an exposed mounting surface with which the module housing can be mounted on a support functioning as an external heat sink. The cooling element and the at least one screw sleeve form a monolithic element with which heat can be conducted from the cooling element to the support via at least the mounting surface.