Resilient PCB Retention for Thermal Expansion and Vibration
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Solution Overview
Problem
Conventional e-machine controllers in turbomachines are bulky, generate significant heat, and are inefficient to manufacture and assemble, with challenges in thermal and electrical isolation, especially in high-temperature and vibrational environments.
Innovation Solution
An integrated e-machine controller with a compact, robust design featuring a support structure, printed circuit board, and a fastener arrangement that includes a resilient member, such as a spring clip, to securely attach the printed circuit board, allowing for thermal expansion and contraction, and providing electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional fastening arrangements are used to attach the printed circuit board, then the controller structure is simple, but the controller cannot effectively manage thermal expansion and contraction, leading to reliability issues in high-temperature environments
Solution Approach 1:
The fastening arrangement transitions from a static rigid connection to a dynamic resilient connection. The resilient member (spring clip) can deflect and adjust its position, allowing the printed circuit board to move slightly in response to thermal expansion and contraction while maintaining secure retention. This dynamic capability enables the system to accommodate dimensional changes without compromising reliability.
Solution Approach 2:
The resilient member changes its physical state between deflected and undeflected positions in response to thermal parameters. As temperature increases and components expand, the spring clip deflects to accommodate the dimensional changes. The resilient nature allows continuous adjustment of the retention force, maintaining reliable connection across varying thermal conditions without requiring complex adjustment mechanisms.
2Productivity
If the printed circuit board is rigidly attached to the support structure, then assembly is simple, but the board cannot accommodate thermal expansion and contraction, causing manufacturing and assembly inefficiencies
Solution Approach 1:
The resilient member provides self-adjusting retention without requiring external adjustment mechanisms or complex assembly procedures. The spring clip automatically deflects to accommodate thermal expansion and contraction of the printed circuit board, eliminating the need for precision alignment or multiple fastening points. This self-service capability maintains secure retention while simplifying the overall assembly process.
3Volume of moving object
If the controller is designed to be compact, then space is saved, but thermal isolation becomes more difficult, generating harmful thermal effects
Solution Approach 1:
The resilient member is extracted from a rigid fastening system and given independent movement capability. The spring clip can deflect and create slight separations or gaps between the printed circuit board and support structure, providing thermal isolation while maintaining mechanical retention. This extraction of the resilient element's freedom of movement allows thermal management in a compact design.
4Reliability
If current carrying parts are electrically isolated with gaps, then electrical safety is improved, but the structure becomes more complex and assembly more difficult
Solution Approach 1:
The resilient member serves multiple functions simultaneously: it provides mechanical retention of the printed circuit board, accommodates thermal expansion and contraction, and maintains electrical isolation through its resilient deflection. This multi-functionality eliminates the need for separate retention and isolation mechanisms, simplifying both manufacturing and assembly while ensuring electrical safety.
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 results in a compact, efficient, and robust controller that effectively manages thermal and vibrational stresses, enhancing manufacturing efficiency and maintaining performance in extreme conditions.
Implementation Method 1
a resilient member that resiliently biases the printed circuit board towards the support structure
Implementation Method 2
allowing for thermal expansion and contraction
Data Source
AI summary
A controller for an e-machine of a turbomachine including a support structure, a printed circuit board, and a fastener arrangement that retains the printed circuit board on the support structure, the fastener arrangement including a resilient member that resiliently biases the printed circuit board towards the support structure.