Rotating Electric Machine Thermal Management via Cap Dissipation
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Solution Overview
Problem
Existing rotating electrical machines with integrated electronic control modules face reliability issues due to weld breakages from thermal expansion coefficient differences between printed circuits and plastic-embedded conductor tracks, and heat dissipation challenges that can damage components.
Innovation Solution
A sealed rotating electrical machine design where the electronic control module's heat is dissipated by a cap acting as a dissipator, using thermally conductive paste and fins for efficient heat transfer, and spacer elements to prevent direct contact between conductor tracks and the printed circuit, ensuring reliable operation and effective heat dispersion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conductor tracks are embedded in plastic material by overmolding, then mechanical support and structural integrity are improved, but reliability deteriorates due to weld breakages from thermal expansion coefficient differences between printed circuit and plastic material
Solution Approach 1:
The patent introduces a support element made of material with thermal expansion coefficient compatible with the printed circuit board, serving as an intermediary between the conductor tracks and the plastic housing. This mediator absorbs thermal expansion differences, preventing stress transmission to the welds while maintaining mechanical support for the conductor tracks.
Solution Approach 2:
The patent segments the support structure into two distinct parts: a rigid support element for mechanical support and electrical stability, and a flexible connection to the plastic housing. This segmentation allows each part to perform its specific function without compromising the other, isolating the conductor tracks from thermal stress.
2Temperature
If heat is dissipated by placing dissipator in contact with printed circuit, then heat dissipation efficiency is improved, but reliability deteriorates as heat adversely affects the condition of printed circuit and connections
Solution Approach 1:
The patent applies local quality by creating a dedicated thermal management zone with the support element that has enhanced thermal conductivity properties. This localized thermal pathway directs heat away from sensitive areas of the printed circuit while maintaining overall circuit integrity, allowing efficient heat dissipation without compromising component conditions.
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 the reliability of the electronic module by preventing weld failures and effectively dissipating heat, thereby maintaining the module's condition and improving the machine's operational stability and efficiency.
Implementation Method 1
the heat generated by the electronic control module is dissipated by the cap which acts as a dissipator
Implementation Method 2
using thermally conductive paste and fins for efficient heat transfer
Implementation Method 3
using thermally conductive paste and fins for efficient heat transfer
Data Source
AI summary
Described is a rotating electrical machine integrating an electronic module comprising a printed circuit, a plurality of electronic power and signal components positioned on the components side of the printed circuit, a plurality of conductor tracks, positioned on the welding side opposite the components side of the printed circuit, which implement the direct electrical connections between the electronic power components; the electronic power and signal components are in contact through a filler with the cap of the electrical machine for allowing an optimum dispersal of the heat generated by them, the contact being guaranteed by elastic elements which press on a support in which the electronic module is housed.