Power Module Cover Sealing for Heat Dissipation and Isolation
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Solution Overview
Problem
Electrical devices face heat management challenges that can lead to safety concerns and performance degradation, while also requiring insulation to prevent unwanted current flow and protection from foreign contaminants.
Innovation Solution
A sealed power module with a cover that joins a heat sink, using gaskets and fasteners for a strong seal, and a thermally conductive and electrically insulating material to secure heat-generating components against the heat sink, ensuring effective heat dissipation and protection from contaminants.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If electrical components are enclosed in a sealed power module, then protection from foreign contaminants is improved, but heat dissipation becomes more difficult
Solution Approach 1:
A thermally conductive and electrically insulating material is introduced as an intermediary between the heat-generating electrical components and the heat sink. This mediator enables efficient heat transfer from the components to the heat sink while maintaining the sealed enclosure for contaminant protection and providing electrical insulation to prevent unwanted current flow.
Solution Approach 2:
The patent employs a composite material that combines thermal conductivity with electrical insulation properties. This composite material serves multiple functions simultaneously: conducting heat away from the components, insulating electrically to prevent current leakage, and enabling the sealed enclosure design.
2Object-affected harmful factors
If a sealed enclosure is used to protect components, then ingress protection is improved, but electrical insulation may be compromised
Solution Approach 1:
The thermally conductive and electrically insulating material acts as an intermediary layer between electrical components at different potential levels. This intermediary provides the necessary electrical insulation to maintain reliability while allowing the sealed enclosure to provide ingress protection.
3Temperature
If heat-generating components are directly coupled to a heat sink, then heat management is improved, but unwanted current flow may occur
Solution Approach 1:
The use of a composite material with both thermal conductivity and electrical insulation properties allows direct coupling of heat-generating components to the heat sink while preventing unwanted current flow. The material conducts heat efficiently in the thermal domain while blocking electrical current in the electrical domain.
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 provides enhanced heat management, maintaining electrical insulation and preventing unwanted current flow while offering a higher ingress protection rating than the external environment, effectively addressing safety and performance concerns.
Implementation Method 1
a thermally conductive and electrically insulating material to secure heat-generating components against the heat sink
Implementation Method 2
a thermally conductive and electrically insulating material to secure heat-generating components against the heat sink
Implementation Method 3
A sealed power module with a cover that joins a heat sink, using gaskets and fasteners for a strong seal
Data Source
AI summary
A cover is disclosed, including: a first gasket that is placed along a portion of the cover that is to join with a heat sink; a second gasket that is placed around a cutout region of the cover, wherein the cover is configured to couple to a circuit board associated with the power module and expose a component on the circuit board through the cutout region; and a fastener that is configured to engage with the heat sink.