Motor Controller Heat Dissipation via Clamped Chip Boss

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Solution Overview

Problem

Conventional motor controllers have limited heat dissipation due to the control chip not being securely attached to the heat dissipation boss, leading to reduced efficiency and potential burnout.

Innovation Solution

A motor controller design where the control chip's outer side surface is clung to the inner side surface of a heat dissipation boss, with a silicone case and compressing bar for secure attachment, and fins for enhanced heat dissipation, along with a potting material to protect the circuit board.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the control chip is not securely attached to the heat dissipation boss, then the structure is simpler and installation is easier, but the heat dissipation performance deteriorates and the control chip may burnout

Engineering Contradiction:

Improveheat dissipation performanceVSAvoidattachment structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The attachment structure is segmented into multiple functional components: a clamping plate that contacts the control chip, a compressing bar that applies force, and a heat dissipation boss with internal threading. This segmentation allows each component to perform its specific function while collectively achieving secure attachment and effective heat dissipation without excessive overall complexity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat dissipation boss is pre-formed with internal threading during the control box manufacturing process, allowing the compressing bar to be subsequently screwed into place. This preliminary action eliminates the need for complex post-assembly operations and ensures proper alignment and secure attachment of the control chip to the heat dissipation structure.

Inventive Principle:

Principle #10Preliminary action

2Reliability

If the control chip is clung to the heat dissipation boss with additional components, then the heat dissipation performance improves, but the installation process becomes more complex

Engineering Contradiction:

Improveheat dissipation performanceVSAvoidinstallation convenience

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The control chip mounting function and heat dissipation function are merged into a single integrated structure. The control chip is positioned between the clamping plate and the heat dissipation boss, creating a combined assembly that simultaneously achieves mechanical attachment and thermal management through the compressing bar and fins.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The compressing bar, when screwed into the heat dissipation boss, automatically generates the compressive force needed to secure the control chip to the heat dissipation surface. The system uses its own structural components to achieve both attachment and heat dissipation without requiring external fastening operations or additional installation steps.

Inventive Principle:

Principle #25Self-service

3Reliability

If fins are added to the heat dissipation boss, then the heat dissipation efficiency increases, but the device complexity and manufacturing difficulty increase

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The heat dissipation boss undergoes a parameter change from a simple cylindrical form to a finned structure with increased surface area. This geometric parameter modification significantly enhances heat dissipation efficiency by exposing more surface to the surrounding air, while the fins can be integrated into the boss during a single casting or machining operation, minimizing additional manufacturing steps.

Inventive Principle:

Principle #35Parameter changes

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 achieves effective heat dissipation, high reliability, and convenient installation, preventing burnout and ensuring the motor controller operates efficiently.

Implementation Method 1

The inner side surface of the heat dissipation boss is clung to by an outer side surface of the control chip

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

The outer side surface of the heat dissipation boss is provided with a plurality of fins

Methodology Applied

Scientific EffectHeat dissipation through fins: Fin

Implementation Method 3

The control chip is sheathed with a silicone case

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS10141809B2Motor controller and motor comprising the same

Publication Date: 2018.11.27 ZHONGSHAN BROAD OCEAN

AI summary

A motor controller including a control box and a control circuit board disposed on the chamber of the control box. A control chip is disposed on the outer edge of the upper surface of the control circuit board. The outer wall of the control box is depressed inward to form a heat dissipation boss. A gap is formed between the bottom of the heat dissipation boss and the inner surface of the bottom of the chamber. The inner surface of the bottom of the chamber is provided with a plurality of supporting bosses. One outer edge of the control circuit board inserts into the gap, which enables the outer side surface of the control chip to cling to the inner side surface of the heat dissipation boss. The control circuit board is supported by upper surfaces of the supporting bosses.