Resilient Bracket Power Module Assembly for Heat Dissipation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional on-board power supplies face challenges with low power density due to large size and inefficient heat dissipation, as well as labor-intensive and costly installation methods, which hinder efficiency and reliability.
Innovation Solution
A power module assembly utilizing a resilient bracket pre-fastened on a housing to form an accommodating space with a circuit board, allowing power devices to be clamped between the bracket and the housing for enhanced heat dissipation and reduced size, along with a simplified fastening method that reduces labor and production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If power devices are directly clamped to the heat-dissipating housing by resilient steel sheet, then heat dissipation is improved, but the power density cannot be effectively raised and the assembly process becomes labor-intensive
Solution Approach 1:
The resilient bracket is divided into multiple pressing sections, each independently pressing power devices at different locations. This segmentation allows for standardized modular assembly while maintaining effective heat dissipation contact for each power device individually.
Solution Approach 2:
The resilient bracket is pre-installed on the heat-dissipating housing before the power devices are mounted. This preliminary action simplifies the assembly process by eliminating the need for workers to manually position and secure each power device individually, thereby improving assembly efficiency while ensuring proper heat dissipation contact.
2Area of stationary object
If power devices are intensively placed together to increase power density, then the occupying area is reduced, but the installation becomes more complex and error-prone
Solution Approach 1:
The resilient bracket acts as an intermediary component between the heat-dissipating housing and the power devices. It provides a standardized interface that simplifies the mounting process, reducing installation complexity and potential errors even when power devices are intensively placed together.
Solution Approach 2:
The resilient bracket's elastic properties allow it to adapt to slight variations in power device dimensions and positions, maintaining reliable contact and heat dissipation even when devices are closely packed, thereby improving installation reliability.
3Strength
If conventional screw fastening method is used to attach power devices to housing, then secure attachment is achieved, but the assembly process becomes labor-intensive and costly
Solution Approach 1:
The resilient bracket replaces the traditional screw fastening mechanism with an elastic pressing system. This substitution maintains secure attachment through continuous elastic force while eliminating the need for multiple screws and complex fastening operations, significantly simplifying the assembly process.
Solution Approach 2:
The resilient bracket's elastic deformation provides self-adjusting pressure that automatically ensures secure contact between power devices and the heat-dissipating housing without requiring precise manual adjustment or multiple fastening points, reducing assembly complexity while maintaining attachment strength.
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 enhances heat dissipation efficiency, reduces the overall size of the power module, and increases power density while simplifying the assembly process and reducing production costs, thereby improving the reliability and efficiency of the power module.
Implementation Method 1
at least one resilient bracket (3, 3a), wherein the resilient bracket (3, 3a) comprises a base section (31) and a pushing section (32)
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present disclosure provides a power module (lb), a power module assembly (1, 1a) and an assembling method thereof. The power module assembly (1, 1a) includes a housing (2), a resilient bracket (3, 3a), a circuit board (4), a power device (5) and a fastening unit (6). The housing (2) includes a first heat-dissipation surface (21). The resilient bracket (3, 3a) is pre-fastened on the housing (2). The resilient bracket (3, 3a) is located near the first heat-dissipation surface (21) and configured with the first heat-dissipation surface (21) to form an accommodating space (7). The circuit board (4) is configured to assemble on the housing (2). The power device (5) is plugged in the circuit board (4) and accommodated in the accommodating space (7). The fastening unit (6) is pre-fastened on the housing (2) and pressing the resilient bracket (3, 3a). While the resilient bracket (3, 3a) pushes against the power device (5), the power device (5) is attached to the first heat-dissipation surface (21).