Module Positioning Parts for Accurate Terminal Alignment
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Solution Overview
Problem
In inverter-type electric-power generators, improving the positional accuracy of connecting terminals is challenging due to the difficulty in referencing the side surface of the heat dissipating substrate when the module case covers the entire circumference, leading to inaccurate electrical connections.
Innovation Solution
A module with a heat dissipating substrate featuring protruding positioning parts, such as corner portions, that protrude beyond the module case, allowing for precise positioning with respect to the housing case, and a module case design that partially covers the heat dissipating substrate, ensuring accurate alignment and connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the module case covers the entire circumference of the heat dissipating substrate, then the module is well protected and sealed, but the positional accuracy of the connecting terminal deteriorates due to inability to reference the side surface
Solution Approach 1:
The module case is designed to cover only a portion of the circumference of the heat dissipating substrate rather than the entire circumference. This segmentation allows the side surface of the heat dissipating substrate to remain exposed, providing a reference for positioning the module while maintaining sealing and protection where needed.
Solution Approach 2:
The invention extracts or removes the module case coverage from the entire circumference, specifically leaving the side surface exposed. This extraction of coverage from the problematic area allows the side surface to serve as a positioning reference, resolving the contradiction between sealing and positioning accuracy.
2Strength
If the module case covers the entire circumference of the heat dissipating substrate, then the module structure is complete and protected, but positioning the module becomes difficult due to lack of reference surface
Solution Approach 1:
The module case coverage is segmented to exclude the side surface area, creating a deliberate gap that serves as a positioning reference. This segmentation maintains structural completeness for protection while facilitating easy positioning during assembly.
Solution Approach 2:
The coverage function is extracted from the side surface region, allowing this area to serve its dual purpose as both a structural component and a positioning reference, thereby improving ease of manufacture and assembly.
3Shape
If the side surface of the heat dissipating substrate is covered, then the module appears compact and sealed, but the connecting terminal cannot be accurately positioned relative to the housing case
Solution Approach 1:
The module case is segmented to provide coverage in most areas for compact appearance while deliberately leaving the side surface exposed. This partial coverage maintains the aesthetic and protective benefits while enabling accurate positioning of the connecting terminal.
Solution Approach 2:
Different regions of the heat dissipating substrate receive different treatments: the top and bottom surfaces are covered for compact appearance and protection, while the side surface remains exposed to provide positioning reference functionality. This local differentiation resolves the contradiction between appearance and positioning accuracy.
Data Source
AI summary
A module includes a heat dissipating substrate including a first surface and a second surface on an opposite side of the first surface, an element arranged on the first surface of the heat dissipating substrate, a connecting terminal arranged on the first surface of the heat dissipating substrate and provided for electrically connecting the element to a wiring substrate arranged on the module, a module case arranged on the first surface in such a manner that a circumference of the heat dissipating substrate is partially covered, and a sealing member sealing the element and a connecting portion of the connecting terminal with the element, wherein the heat dissipating substrate includes a positioning part for positioning the module with respect to the housing case, and the positioning part protrudes to an outer side of the module case.