Power Electronics Assembly With Insulated Sleeve Heat Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Power electronics assemblies used in electric vehicles generate significant heat, leading to thermal expansion and potential damage to components, as existing solutions fail to effectively manage heat dissipation and electrical insulation between circuit boards.

Innovation Solution

A power electronics assembly design that couples a composite material substrate to an insulated metal substrate using a bolt and electrically conductive sleeve, with an electrically insulating sleeve providing insulation and maintaining a predetermined distance to prevent electrical conduction and thermal transfer, while using a heat sink to dissipate heat.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If circuit boards are coupled closely to reduce assembly size, then compactness is improved, but thermal damage and electrical conduction risks worsen

Engineering Contradiction:

Improveassembly sizeVSAvoidthermal damage and electrical conduction risks

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an insulating sleeve as an intermediary component between the bolt and circuit boards. This sleeve provides both electrical insulation and thermal isolation, allowing the circuit boards to be coupled closely while preventing harmful thermal and electrical interactions. The intermediary element enables compact assembly without compromising safety or component integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If heat-generating components are placed close to power-providing components, then assembly compactness is improved, but heat dissipation and component durability worsen

Engineering Contradiction:

Improveassembly volumeVSAvoidheat management

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The insulating sleeve acts as a thermal intermediary, blocking direct heat transfer from power-providing components to heat-sensitive circuit boards. This allows compact placement of components while maintaining effective thermal management through the insulating barrier.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the assembly into distinct thermal zones by introducing the insulating sleeve, separating heat-generating components from heat-sensitive components. This segmentation enables independent thermal management of different functional areas within the compact assembly.

Inventive Principle:

Principle #1Segmentation

3Reliability

If electrical insulation distance is increased to prevent conduction, then electrical safety is improved, but assembly size increases

Engineering Contradiction:

Improveelectrical insulationVSAvoidassembly size

Core Design Contradiction:

ReliabilityVSVolume of moving object

Solution Approach 1:

The insulating sleeve performs multiple functions simultaneously: it provides electrical insulation, thermal isolation, and mechanical spacing. This multi-functionality achieves reliable electrical insulation without requiring additional separate components, thereby avoiding increase in overall assembly size.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the functions of electrical insulation, thermal protection, and mechanical positioning into a single insulating sleeve component. This consolidation achieves multiple protection goals while maintaining compact assembly dimensions.

Inventive Principle:

Principle #5Merging (Combining)

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 effectively isolates heat-generating components from power-providing components, preventing thermal damage and ensuring reliable electrical coupling, thereby enhancing the durability and efficiency of power electronics assemblies in vehicles.

Implementation Method 1

heat sink to dissipate heat

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

heat sink to dissipate heat

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 3

electrically insulating sleeve providing insulation and maintaining a predetermined distance to prevent electrical conduction and thermal transfer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUSRE49723E1Power electronics assembly

Publication Date: 2023.11.07 CSL2 LTD

AI summary

A power electronics assembly for an electric motor controller. The power electronics assembly comprises an insulated metal substrate, a composite material substrate, and a bolt having a bolt head and a bolt shaft for mechanically coupling the composite material substrate to the insulated metal substrate. The power electronics assembly also includes an electrically conductive sleeve configured to be held between a first electrical contact carried by the insulated metal substrate and a second electrical contact carried by the composite material substrate and the bolt is configured to clamp the composite material substrate to the insulated metal substrate to force the electrically conductive sleeve against the first electrical contact and the second electrical contact.