Multilayer Mounting Bracket for Thermal and Electrical Management
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Vehicle components, such as mounting brackets, face challenges in balancing weight reduction with the need for strength, heat conductivity, and electrical conductivity, as metal brackets are heavy and costly, while plastic ones lack electrical connectivity.
Innovation Solution
A multilayer mounting bracket composed of a dual-conductive polymer layer for electrical and thermal conductivity, and an insulating polymer layer with an endothermic blowing agent for thermal insulation, which acts as a heat sink and EMI shield, reducing heat transfer to the chassis and providing electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal mounting brackets are used, then strength and electrical conductivity are improved, but weight increases and manufacturing cost increases
Solution Approach 1:
The patent applies composite materials by combining polymer matrix with carbon fiber reinforcements and metal inserts to create a mounting bracket that achieves metal-like strength while maintaining plastic-like weight characteristics. The composite structure allows the bracket to withstand mechanical loads equivalent to metal brackets without the associated weight penalty.
Solution Approach 2:
The patent implements local quality by strategically placing metal inserts or conductive elements only in specific regions of the mounting bracket where electrical conductivity and strength are most critical, rather than making the entire bracket metallic. This localized approach provides necessary performance characteristics while minimizing overall weight and material cost.
2Reliability
If metal mounting brackets are used, then electrical conductivity is improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by incorporating conductive elements or metal inserts only in specific areas where electrical connectivity is required, rather than making the entire bracket electrically conductive. This reduces material costs and manufacturing complexity while maintaining necessary electrical connection capabilities.
Solution Approach 2:
The patent uses composite materials combining insulating polymer with localized conductive components, achieving the necessary electrical connectivity through the composite structure rather than requiring a fully metallic construction, thereby reducing manufacturing cost.
3Weight of moving object
If plastic mounting brackets are used, then weight is reduced and manufacturing cost is reduced, but electrical conductivity and heat conductivity deteriorate
Solution Approach 1:
The patent applies composite materials by embedding carbon fiber reinforcements, graphite particles, or metal flakes within the polymer matrix to provide electrical conductivity pathways while maintaining the lightweight characteristics of plastic brackets. The composite structure delivers both weight advantage and electrical connectivity.
Solution Approach 2:
The patent implements local quality by adding conductive fillers or reinforcements only in regions where electrical conductivity is needed, allowing the majority of the bracket to remain lightweight plastic while providing targeted electrical pathways where required.
4Weight of moving object
If plastic mounting brackets are used, then weight is reduced, but heat conductivity deteriorates
Solution Approach 1:
The patent applies composite materials by incorporating thermally conductive fillers such as aluminum oxide, boron nitride, or carbon-based materials into the polymer matrix to enhance heat dissipation capability while preserving the lightweight advantage of plastic brackets.
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 achieves lightweight, cost-effective mounting brackets with enhanced thermal and electrical conductivity, effective heat dissipation, and insulation, addressing the limitations of traditional metal and plastic brackets.
Implementation Method 1
The carbon material endows upon the first layer, a desirable electrical conductivity characteristic and a desirable thermal conductivity characteristic
Implementation Method 2
a second layer made of a polymer that includes an endothermic blowing agent
Implementation Method 3
The endothermic blowing agent endows upon the second layer, a desirable thermal insulation characteristic
Implementation Method 4
can also operate as an electromagnetic interference (EMI) shield
Data Source
AI summary
Example embodiments described in this disclosure are generally directed to a mounting bracket for deployment in a vehicle. In one embodiment, a multilayer mounting bracket includes a first layer made of a dual-conductive polymer and a second layer made of a polymer that includes an endothermic blowing agent. The dual-conductive polymer includes carbon material that renders the first layer electrically conductive and also includes graphite material that renders the first layer thermally conductive. The endothermic blowing agent renders the second layer thermally insulative. An electronic module such as an engine controller can be mounted upon the first layer, which operates as a heat sink to dissipate heat generated by the electronic module and also operates as an electromagnetic interference (EMI) shield. The second layer prevents heat from being transferred from the first layer into another electronic module that may be mounted upon the mounting bracket.