Power Tool PCB Conductor Heat Dissipation
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Solution Overview
Problem
Power tools, such as electric drills, experience increased heat generation and malfunction due to high currents flowing through their printed circuit boards, leading to rapid heat buildup in the tool's housing.
Innovation Solution
A printed circuit board assembly with a main board featuring exposed conductive and insulation portions, a semiconductor power device, and a conductor attached to the conductive portion, which provides an additional path for current flow, reducing heat generation by distributing the current effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If current flows through the printed circuit board, then the power tool can operate, but heat is generated causing malfunction
Solution Approach 1:
The patent divides the current path into two separate segments: one through the printed circuit board (for control signals) and another through a dedicated conductor (for high current). This segmentation prevents the concentration of high current through the PCB, reducing heat generation while maintaining operational reliability.
Solution Approach 2:
The patent introduces a dedicated conductor as an intermediary element to carry high current between the power source and the semiconductor power device. This intermediary path bypasses the PCB for high current flow, allowing the PCB to handle only control signals and reducing overall heat generation in the housing.
2Power
If high current flows through the printed circuit board, then power delivery is sufficient, but heat generation increases rapidly
Solution Approach 1:
The current delivery function is segmented between the PCB trace (for low current control) and the dedicated conductor (for high current power delivery). This segmentation enables sufficient power delivery through the low-resistance conductor while minimizing energy loss as heat in the PCB.
Solution Approach 2:
The patent changes the physical parameters of the current path by using a dedicated conductor with lower resistance compared to the PCB trace. This parameter change allows high current to flow with reduced resistive heating, maintaining power delivery efficiency while reducing energy loss.
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 heat generation in the printed circuit board, preventing malfunctions in power tools by managing current flow and heat dissipation efficiently.
Implementation Method 1
a conductor (330) attached to the conductive portion (311); wherein the conductive portion (311) electrically connects to the semiconductor power device (320), and the conductor (330) electrically connects to the conductive portion (311)
Implementation Method 2
When the current which is flowing through the printed circuit board gets greater, the heat which is generated by the printed circuit board gets greater
Data Source
AI summary
A power tool and a printed circuit board for use therewith. The power tool has an electric motor and a power source. The printed circuit board assembly has a main board having a conductive portion, a semiconductor power device, and a conductor attached to the conductive portion. The conductive portion electrically connects to the semiconductor power device and the conductor electrically connects to the conductive portion. When current is flowing through the printed circuit board, the heat and the voltage loss generated by the printed circuit board can be reduced.