Power Module Heat-Sink Cover Clamping for Compact Cooling
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Solution Overview
Problem
Conventional power module cooling arrangements require additional structural elements for screw fastening, which compromise thermal performance and increase production costs due to the need for reinforced ribs and thickened heat sinks, and complex die designs for die-cast heat sinks.
Innovation Solution
The use of a heat-sink cover that clamps the heat sink in place through form or force fit configurations, reducing or eliminating the need for screw connections and allowing for a more efficient and space-saving cooling solution by maintaining the existing shape of the heat sink and optimizing its heat dissipation capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If screw connections are used to fasten the heat sink to the housing and power units, then reliable mechanical fastening is achieved, but the thermal performance deteriorates due to thermal resistance at screw interfaces and the need for thickened heat-sink roots
Solution Approach 1:
A cover element is introduced as an intermediary component between the heat sink and the housing. This cover element provides screw connection points without requiring modifications to the heat sink itself, thereby eliminating thermal bridges at screw interfaces while maintaining secure mechanical fastening through the cover's attachment to the housing
Solution Approach 2:
The fastening function is segmented from the heat sink structure. Instead of integrating screw holes and reinforcement directly into the heat sink, the fastening system is separated into a distinct cover element that attaches to the housing independently, allowing the heat sink to maintain its optimized thermal geometry
2Strength
If reinforced ribs and thickened heat-sink roots are added for screw fastening, then mechanical strength is improved, but the device complexity and production costs increase
Solution Approach 1:
The cover element serves as a mediator that absorbs all fastening-related structural requirements. It contains all screw connection points, reinforcement, and mounting features, allowing the heat sink to remain structurally simple and optimized for thermal performance without any fastening-related modifications
Solution Approach 2:
The cover element replicates the fastening functionality of traditional heat sink designs without copying the structural modifications. It provides the necessary mechanical strength and screw attachment points while the heat sink itself maintains its original, simplified geometry for optimal heat dissipation
3Strength
If the heat sink shape is modified to accommodate screw connections, then fastening requirements are met, but the manufacturing precision requirements increase due to additional work steps like over-milling
Solution Approach 1:
The cover element acts as an intermediary that takes on all manufacturing complexity for fastening purposes. It can be manufactured with all necessary screw holes, threads, and reinforcement features without affecting the heat sink's surface quality, as no post-processing like over-milling is required on the heat sink itself
Solution Approach 2:
The fastening features are extracted from the heat sink manufacturing process entirely. All screw connections, reinforcement, and mounting structures are moved to the separate cover element, eliminating the need for additional precision machining steps on the heat sink and maintaining its surface integrity
Data Source
AI summary
An arrangement for cooling a power module with at least one power unit in a housing is provide, the arrangement having at least one heat sink, in which the arrangement for cooling has at least one heat-sink cover, and at least a part of the power module, in particular the housing, at least a part of the heat sink and/or at least a part of the heat-sink cover are/is configured in such a way that, after attachment of the heat-sink cover, the heat sink is fixed in the housing, in particular by way of clamping, through interaction of the configuration of heat sink, heat-sink cover and/or housing. Also, a power module having such an arrangement for cooling a power module is provided.