Power Electronic Device Potting With Closed Contact Sleeves

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Solution Overview

Problem

Existing methods for producing power electronic devices face issues with potting compound penetration into metallic sleeves, rendering them unusable for plug contacts, and require precise tolerances that complicate the production process.

Innovation Solution

The method involves using metallic sleeves bonded at a right angle to the substrate, encapsulating the power semiconductor and sleeves with a potting compound while ensuring the sleeve ends facing away from the substrate are closed to prevent compound penetration, and then machining these ends to accommodate plug contacts after encapsulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the substrate thickness and distance from openings to substrate are kept precise to prevent potting compound penetration, then the reliability of connection is improved, but the manufacturing complexity and tolerance requirements increase

Engineering Contradiction:

Improveconnection reliabilityVSAvoidproduction process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The sleeve ends are closed before the potting compound is applied, preventing compound penetration into the sleeves. This preliminary protective action eliminates the need for precise thickness control of the substrate and precise positioning of openings, thereby reducing manufacturing complexity and tolerance requirements while maintaining connection reliability

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The closed sleeve ends act as an intermediary barrier between the potting compound and the interior of the sleeves. This mediator prevents the harmful interaction (compound penetration) without requiring precise dimensional control of other components, thus simplifying the production process while ensuring reliable connections

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If the sleeves are left open to accommodate plug contacts, then the ease of operation is improved, but the risk of potting compound penetration increases

Engineering Contradiction:

Improveplug contact insertionVSAvoidpotting compound penetration

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The sleeves are closed before the potting compound is applied, preventing compound penetration. After encapsulation, the closed ends are machined to create openings that accommodate plug contacts. This sequence ensures both protection during manufacturing and ease of operation in the final product

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The sleeve structure is segmented into two functional parts: the closed end that prevents compound penetration during manufacturing, and the machined opening that accommodates plug contacts for ease of operation. This segmentation allows both requirements to be satisfied simultaneously

Inventive Principle:

Principle #1Segmentation

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 approach prevents sleeve contamination, simplifies the production process, reduces material waste, and allows for efficient electrical contacting of control and signal contacts with small cross-sections, facilitating compact and cost-effective power electronic device manufacturing.