Rigid Intermediate Part for Stacked Electronic Boards in Electrical Supercharger
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Solution Overview
Problem
In electric superchargers, the limited space and heat dissipation requirements pose challenges in effectively separating and assembling power and control cards without contact, while ensuring efficient heat transfer and electrical connection.
Innovation Solution
A rigid intermediate part is used to fix and control the distance between superposed electronic power and control cards, facilitating assembly, heat dissipation, and electrical connection, with features like insulating material, metal inserts, and indexing pins for secure fixing and heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the power card and control card are placed close together to save space, then the space utilization is improved, but the risk of contact between components and electrical interference increases
Solution Approach 1:
The patent introduces a rigid intermediate part positioned between the power card and control card. This intermediary component serves multiple functions: it maintains precise spacing to prevent component contact, provides mechanical support for both cards, and enables electrical connection through integrated conductive elements. The intermediate part acts as a mediator that allows close placement while maintaining electrical isolation and connection reliability.
2Stability of the object's composition
If the two cards are firmly fixed together in a single block, then the assembly stability is improved, but the heat dissipation from power components becomes more difficult
Solution Approach 1:
The patent segments the assembly into distinct functional zones using the rigid intermediate part. The intermediate part creates separate thermal management zones: one side for heat-generating power components and another side for control components. This segmentation allows independent thermal treatment of each card while maintaining mechanical stability through the intermediate structure, enabling heat dissipation pathways to be optimized for each functional block.
3Length of stationary object
If the intermediate part is made thin to reduce space, then the space between cards is reduced, but the structural strength and heat dissipation capability are compromised
Solution Approach 1:
The rigid intermediate part is designed as a composite structure combining materials with different properties. It integrates electrically insulating materials for electrical isolation with thermally conductive pathways for heat dissipation. The composite construction allows the intermediate part to maintain minimal thickness while providing sufficient mechanical strength, electrical isolation, and thermal management capabilities through multi-functional material integration.
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 allows for precise spacing, protection against electrical welding, efficient heat dissipation, and reduced part count, enhancing the integration and performance of electric superchargers by ensuring reliable electrical connections and heat management.
Implementation Method 1
the intermediate part makes it possible to dissipate the heat present in one of the cards towards the other card by means of said intermediate part
Implementation Method 2
the power board made on an insulated metal substrate plated on the bottom of the compressor box, so as to ensure the heat dissipation of the supercharger
Data Source
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AI summary
The invention relates to an electrical supercharger including: - a housing; - a rotary electrical machine; - a compression member coupled with said rotary electrical machine; and - an electronic device for supplying electrical power to the electrical machine. Said compressor is characterized in that said electronic device includes two stacked electronic boards (54, 56) and a rigid intermediate component (10) that is placed between said two electronic boards (54, 56) so that said boards are attached to each other by means of said intermediate component (10) and the electronic connection device is attached to the housing by means of said rigid intermediate component.