Power Conversion Device Heat-Dissipating Base Mounting
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Solution Overview
Problem
The on-board charge module (OBCM) in electric vehicles faces challenges due to the vibration and gravitational forces causing electronic components to detach from the printed wiring board, leading to poor electronic connections and increased maintenance costs.
Innovation Solution
A power conversion device design featuring a heat-dissipating base with a three-dimensional structure and potting glue to securely mount the electromagnetic inductive module, ensuring stable electrical connections and improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electronic components are connected to the printed wiring board by welding joints, then the electronic connection is established, but the vibration of electronic components causes fracture in the welding joints or bending of the printed wiring board
Solution Approach 1:
The patent introduces a fixing structure as an intermediary component between the electronic component and the printed wiring board. This fixing structure provides additional mechanical support and distributes the stress, preventing direct stress concentration on the welding joints while maintaining electrical connection integrity.
Solution Approach 2:
The patent adds a spatial dimension to the connection by introducing a fixing structure that extends beyond the traditional planar welding joint. This three-dimensional fixing structure provides support from multiple directions, preventing both welding joint fracture and printed wiring board bending through distributed mechanical constraint.
2Power
If large and heavy electronic components are used, then the power conversion function is achieved, but the gravity of electronic components causes bending of the printed wiring board
Solution Approach 1:
The patent segments the support function from the electrical connection function. The fixing structure provides mechanical support to bear the gravity of heavy electronic components, while the welding joints focus on providing electrical connection. This segmentation allows the printed wiring board to handle electrical signals without bearing excessive mechanical load.
Solution Approach 2:
The fixing structure acts as a mediator that bears the gravitational load of heavy electronic components, preventing this load from being transmitted directly to the printed wiring board. This intermediary structure maintains the structural integrity and stability of the printed wiring board while allowing the use of powerful electronic components.
3Ease of manufacture
If traditional assembly methods are used, then the manufacturing process is simple, but the assembling time is long and maintenance cost is high
Solution Approach 1:
The patent merges the fixing function and the electrical connection function into an integrated assembly process. The fixing structure is designed to be installed simultaneously with the electrical connection, combining multiple operations into a single assembly step. This reduces the total number of assembly steps and improves manufacturing efficiency without significantly increasing process complexity.
Data Source
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AI summary
A method for assembling a power conversion device is provided. The method includes mounting an electronic component on a heat-dissipating base, and electrically connecting a printed wiring board with the electronic component mounted on the heat-dissipating base.