Power Module Interlocking Assembly for TIM Bond-Line Control
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing power modules in traction inverters face challenges in achieving correct Bond-Line-Thickness (BLT) control of Thermal-Interface-Material (TIM) and proper alignment with heat sinks, which affects performance and reliability.
Innovation Solution
The implementation of interlocking features on power modules and heat sinks, combined with a layer of thermal interface material, facilitates accurate alignment and enhances bonding integrity by controlling bond line thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional power module assembly methods are used, then the assembly process requires additional alignment tools, but the alignment precision between power module and heat sink is insufficient
Solution Approach 1:
The power module incorporates self-aligning features (protrusions and recesses) that automatically guide alignment during assembly, eliminating the need for external alignment tools and operators. The interlocking structure itself performs the alignment function that previously required separate tools.
Solution Approach 2:
The interlocking features (protrusions and recesses) act as intermediary elements between the power module and heat sink, providing a mechanical interface that ensures precise alignment and bonding while eliminating the need for additional alignment tools.
2Strength
If Bond-Line-Thickness Control is not implemented, then the assembly process is simpler, but the bonding integrity between power module and heat sink is compromised
Solution Approach 1:
The interlocking structure automatically controls the bond line thickness through its geometric design, with the protrusion height and recess depth determining the TIM thickness. This self-regulating mechanism ensures consistent bonding integrity without requiring external control systems or complex assembly procedures.
Solution Approach 2:
The interlocking features are pre-designed with specific dimensions that predetermined the bond line thickness. The protrusion and recess geometries are configured in advance to ensure the thermal interface material achieves the optimal thickness for bonding integrity, eliminating the need for real-time control during assembly.
3Strength
If interlocking features are added to the power module, then the bonding strength increases, but the manufacturing complexity of the power module increases
Solution Approach 1:
The interlocking features are designed as discrete protrusions and recesses that can be independently manufactured and integrated into the power module structure. This segmentation allows the features to be added through modular manufacturing processes, reducing the overall manufacturing complexity compared to creating entirely new monolithic structures.
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 solution eliminates the need for additional tools during assembly, increases the strength of the bonding between the power module and heat sink, and reduces the risk of failure or cracking by ensuring a strong, uniform interlocking bonding.
Implementation Method 1
the surface of the at least one heat sink includes a layer of thermal interface material
Data Source
AI summary
A system includes a power module, wherein the power module includes an interlocking feature on a first surface of the power module; and at least one heat sink, wherein the surface of the at least one heat sink includes a layer of thermal interface material.