Power Module Frame for Precise Control Unit Alignment
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Solution Overview
Problem
The precise alignment of power units with control units in power modules is challenging due to inaccuracies, affecting the functionality of the power module.
Innovation Solution
A power module design featuring a frame with a star-shaped protruding section for centering the control unit, which engages with the heat sink and control unit, providing precise positioning without the need for additional stabilization or management tools, and utilizing a substrate with conductive and thermally conductive layers for efficient cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If precise alignment methods are used to position the control unit relative to the power unit, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The frame structure performs self-alignment through its geometric design. The star-shaped second protruding section automatically orients itself relative to the control unit's opening during assembly, eliminating the need for external alignment tools or complex positioning mechanisms. The substrate acts as a self-guiding element that directs the control unit into the correct position.
Solution Approach 2:
The star-shaped contour of the second protruding section provides asymmetric geometric features that enable unique orientation and positioning. This asymmetric design allows the control unit to be positioned in only one correct orientation, ensuring precise alignment without requiring complex alignment procedures or additional stabilization tools.
2Stability of the object's composition
If additional stabilization tools are used to ensure proper positioning, then positioning stability is improved, but device complexity increases
Solution Approach 1:
The frame combines multiple functions into a single structure: positioning, centering, and stabilization are all achieved through the integrated frame design with its star-shaped protruding section. This merging of functions eliminates the need for separate stabilization tools, reducing device complexity while maintaining positioning stability.
Solution Approach 2:
The star-shaped contour provides geometric constraints that inherently stabilize the connection between the frame and control unit. The shaped protruding section fits into the control unit's opening in a way that provides inherent mechanical stability without requiring additional stabilization elements.
3Stability of the object's composition
If conventional housing designs are used to enclose the power unit, then structural stability is improved, but material usage increases
Solution Approach 1:
The invention extracts only the essential enclosing and positioning functions from a conventional housing design. The frame provides the necessary structural stability and positioning capabilities without the bulk and material consumption of a full conventional housing, achieving a minimalist yet effective enclosure.
Solution Approach 2:
The frame's geometric parameters, particularly the star-shaped contour with its specific leg dimensions and angles, are optimized to provide maximum structural stability with minimum material. The design transforms the conventional approach of using more material for stability to using precisely engineered geometric parameters.
4Ease of manufacture
If round protruding sections are used for engagement, then manufacturing simplicity is improved, but positioning precision worsens
Solution Approach 1:
The star-shaped contour with its multiple legs provides asymmetric geometric features that enable precise positioning and orientation. Unlike a round section that can rotate freely, the star shape with its specific number of legs (typically 3 or 4) creates unique engagement points that ensure accurate positioning while remaining manufacturable through standard molding or machining processes.
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 simplifies the positioning process, reduces material usage, and ensures stable and efficient cooling, minimizing the risk of misalignment and scrap, while also reducing costs and tool complexity.
Implementation Method 1
at least one thermally conductive layer, wherein the thermally conductive layer preferably comprises ceramic
Data Source
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AI summary
The invention relates to a power module (10) comprising: at least one heat sink (8); at least one power unit (11), wherein the power unit (11) comprises at least one semiconductor device (6) and a substrate (7); a device (1) for enclosing the power unit (11), which is formed at least partially within and/or on the heat sink (8), and for centering a control unit (20) with respect to the power unit (11), wherein the device (1) comprises: a frame (2), wherein the frame (2) at least partially, preferably completely, surrounds the substrate (7); at least one first projecting section (3), wherein the first projecting section (3) engages in a recess or an opening (12) of the heat sink (8);at least a second preceding section (4), wherein the second preceding section (4) is configured to engage in a recess or opening or notch (21) of a control unit (20) comprising at least one electronic component (24), wherein a contour of the second preceding section (4) is configured in cross-section at least substantially in the form of a star, wherein the star has at least a first leg, a second leg and a third leg.