Electric Component Insulation Testing via Segmented Conductor Paths
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Solution Overview
Problem
Existing electric components, such as vehicle control devices, face challenges in reliably detecting insulation faults between a circuit board and a conductive housing, especially at high operating voltages, due to the insulation being compromised by conductive particles in heat-conductive pastes, which can lead to unsafe electrical connections.
Innovation Solution
The solution involves a conductor path structure with interruptions that are electrically bridged by securing elements, allowing for reliable insulation testing and ensuring the main section remains galvanically separated from the housing, while the connection section is electrically connected, enabling detection of insulation faults and enhancing safety against voltage faults.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the circuit board is thermally connected to the housing via heat-conductive paste, then heat removal from electronic components is improved, but insulation reliability deteriorates due to conductive particles in the paste
Solution Approach 1:
The conductor path structure is divided into a first conductor path part and a second conductor path part with an interruption between them. This segmentation allows the insulation measurement to be performed on the first part while the second part remains electrically isolated, preventing false readings caused by conductive particles in the heat-conductive paste.
Solution Approach 2:
The securing element acts as an intermediary that bridges the interruption in the conductor path structure only after insulation measurement is completed. This allows the measurement to be performed on an isolated circuit while the final electrical connection is established by the securing element, separating the measurement phase from the operational phase.
2Adaptability or versatility
If the circuit board is electrically connected to the housing, then functional coupling is achieved, but insulation fault detection becomes impossible in the final state
Solution Approach 1:
The insulation measurement is performed before the securing element is installed. The conductor path structure is designed with an interruption that prevents electrical connection during the measurement phase, allowing insulation faults to be detected before the circuit board is permanently mounted and electrically connected to the housing.
Solution Approach 2:
The electrical connection state of the conductor path structure is dynamic - initially interrupted for measurement purposes, then completed by the securing element during operation. This dynamic configuration allows the system to transition between measurement mode (isolated) and operational mode (connected), resolving the conflict between detectability and functionality.
3Reliability
If the conductor path structure is continuous, then electrical connectivity is improved, but insulation measurement reliability deteriorates due to parallel thermal connection
Solution Approach 1:
The conductor path structure is segmented into two separate parts with an interruption between them. The first conductor path part is used for insulation measurement while the second part is connected to the housing, preventing parallel thermal connection paths from interfering with the measurement. This segmentation ensures that the measurement current flows only through the intended path.
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 configuration allows for comprehensive insulation testing and ensures reliable electrical insulation, preventing potential faults caused by conductive pastes, thereby increasing safety and reliability in high-voltage applications.
Implementation Method 1
The circuit board of a control device is thermally connected to the housing of the control device in order to be able to remove the lost heat arising in the electronic components
Implementation Method 2
the interruption assigned to the securing element is electrically bridged by the securing element when the securing element secures the component support on the housing
Data Source
AI summary
An electric component has a housing part and a component support which is provided with a conductor path structure. The conductor path structure has an interruption, by which a connection section of the conductor path structure is galvanically separated from a main section of the conductor path structure. The component support is arranged on the housing part such that a heat-conductive connection is produced between the component support and the housing part. The main section remains galvanically separated from the housing part. The electric resistance between the main section of the conductor path structure and the housing part is measured. The component support is secured to the housing part by a securing element. The interruption is electrically bridged by the securing element and the main section is electrically conductively connected to the housing component.