Angled Metal-Support Power Module for Thermal Cycle Reliability
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Solution Overview
Problem
Existing power electric modules face significant mechanical and thermal stresses due to temperature cycles, leading to increased failure probabilities.
Innovation Solution
The power electric module features metallic supports with angled metallic portions that form a substrate, allowing for tri-modal heat dissipation and reducing the risk of ceramic substrate weakening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a ceramic substrate is used to provide electrical insulation and heat transfer, then electrical insulation is achieved, but the substrate is weakened by thermal cycles causing mechanical stresses and increased failure probability
Solution Approach 1:
The patent changes the material parameter of the substrate from ceramic to metallic (aluminum or copper), fundamentally altering the thermal and mechanical properties. This material substitution eliminates the substrate's vulnerability to thermal cycle-induced mechanical stresses while maintaining electrical insulation through a separate insulating layer, thereby resolving the contradiction between reliability and substrate strength under thermal conditions.
Solution Approach 2:
The invention creates a composite structure where a metallic substrate (aluminum or copper) is combined with an insulating layer (such as a plastic housing or insulating material). This composite approach allows the metallic substrate to handle thermal and mechanical stresses effectively while the insulating layer provides the necessary electrical insulation, thus resolving the contradiction between the need for thermal stability and electrical insulation.
2Temperature
If conventional single-mode heat dissipation is used, then device simplicity is maintained, but heat dissipation effectiveness is insufficient under severe temperature cycles
Solution Approach 1:
The metallic substrate in the invention serves multiple functions simultaneously: it acts as a heat spreader, provides structural support, and enables multi-directional heat dissipation through its high thermal conductivity. The insulating layer also serves dual purposes by providing electrical insulation and contributing to the overall thermal management. This multi-functionality approach improves heat dissipation effectiveness without proportionally increasing device complexity.
Solution Approach 2:
The insulating layer acts as an intermediary element between the metallic substrate and the external environment, facilitating thermal management while maintaining electrical isolation. This intermediary structure enables the system to achieve effective heat dissipation through the metallic substrate while protecting against electrical breakdown, thus improving temperature management without excessive complexity increase.
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 configuration enhances heat dissipation effectiveness and reduces the likelihood of module failure by mitigating mechanical and thermal stresses.
Implementation Method 1
The supports of the electric power module, in which the electric power currents circulate, allow simultaneous tri-modal heat dissipation, by conduction, convection and radiation
Implementation Method 2
The supports of the electric power module, in which the electric power currents circulate, allow simultaneous tri-modal heat dissipation, by conduction, convection and radiation
Implementation Method 3
The supports of the electric power module, in which the electric power currents circulate, allow simultaneous tri-modal heat dissipation, by conduction, convection and radiation
Implementation Method 4
each power component being fixed to two metal portions of two separate supports by being positioned between said two metal portions, the electrical power module being arranged so that electric power currents originating from or destined for the power components flow in the metal portions of the supports
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
The invention relates to an electrical power module including power components (21, 22) and mountings (30) each comprising at least one metal portion (31; 32), the metal portions of the mountings forming a substrate of the electrical power module (1), at least one mounting (30a, 30b, 30c, 30d, 30e) comprising two metal portions oriented with respect to one another by an orientation angle of more than 0°, each power component being secured to two metal portions of two separate mountings by being positioned between said two metal portions, the electrical power module being arranged so that electrical power currents coming from or directed towards the power components circulate in the metal portions of the mountings.