Power Module Explosion Protection Sealing Mechanism
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power modules face reliability issues during thermal faults, as organic insulation materials expand and combust, leading to a high risk of damage and splintering, which can affect neighboring modules.
Innovation Solution
A power module with a pressurizable sealing means, featuring a wavy or folded ring structure and piston rings, that absorbs kinetic energy and minimizes explosion effects by sealing the housing against explosive gases, using materials like polymers, siloxane, and composite materials to enhance operational safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If organic insulation materials are used in power modules, then insulation performance is improved, but explosion risk and gas volume expansion increase during thermal faults
Solution Approach 1:
The patent removes organic insulation materials from the power module housing and replaces them with inorganic materials such as ceramic coatings or glass ceramics. This extraction of the harmful organic component eliminates the source of explosive gas generation while maintaining the necessary insulation properties through inorganic alternatives.
Solution Approach 2:
The patent creates an inert environment by using inorganic insulation materials that do not combust or generate explosive gases during thermal faults. The ceramic or glass ceramic materials provide an non-flammable, inert atmosphere within the housing, preventing explosion reactions that would occur with organic materials.
2Object-affected harmful factors
If inorganic insulation materials replace organic materials, then explosion risk is reduced, but insulation performance may deteriorate
Solution Approach 1:
The patent employs composite material structures combining ceramic particles or glass ceramic layers with binding agents to achieve both high insulation performance and explosion protection. The composite structure allows optimization of electrical insulation properties while maintaining the non-combustible characteristics of inorganic materials.
Solution Approach 2:
The patent modifies the physical and chemical parameters of the insulation material by selecting inorganic substances with specific dielectric constants, thermal stability, and mechanical properties. These parameter changes ensure that the inorganic materials provide adequate insulation performance comparable to or exceeding organic materials while eliminating explosion hazards.
3Reliability
If sealing means is pressurized into sealing position during explosion, then sealing effectiveness is improved, but kinetic energy absorption requires deformation of sealant
Solution Approach 1:
The patent uses a sealing means with flexible, deformable characteristics that can be pressurized into the sealing position during normal operation. In the event of an explosion, this sealing means can deform to absorb kinetic energy while maintaining the seal, utilizing the flexibility of the sealant material to accommodate pressure changes without compromising sealing effectiveness.
Solution Approach 2:
The sealing means is pre-positioned and pre-pressurized into the sealing position between the housing part and housing cover before any explosion occurs. This beforehand cushioning ensures that the seal is already in place to contain explosive gases, and the sealant's deformability provides additional energy absorption capacity during the explosion event.
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 significantly reduces the risk of damage to adjacent power modules by effectively containing explosive gases and converting kinetic energy into deformation energy, thereby enhancing operational safety and reliability during faults.
Implementation Method 1
the pressurization of the sealant into the sealing position can be accompanied by a deformation of at least parts of the sealant. Consequently, the sealant at least partially absorbs kinetic energy of the explosion gases by converting it into deformation energy of the sealant.
Implementation Method 2
the sealing means can be pressurized into the sealing position by means of an overpressure occurring within the housing part and housing cover and sealing means.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The power module is formed with a housing comprising a housing part, a housing cover and a sealing agent which can be pressurized into a sealing position that seals the housing part and the housing cover together.