Segmented Heatsink Power Module for Heat Transfer and Insulation

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Solution Overview

Problem

Existing power electronics modules face challenges in efficiently evacuating heat due to high thermal resistance from insulating layers, particularly ceramic materials, which limit the heat transfer to heatsinks, and risk electrical short circuits from high potential differences.

Innovation Solution

A power electronics module design featuring diverging lateral faces on heatsink portions, insulated by electrically conductive elements, uses thermomechanical transition layers and insulators to enhance heat transfer while maintaining electrical insulation, avoiding short circuits through increased distance and flared faces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a ceramic insulating layer is used between conductive elements to ensure electrical insulation, then electrical insulation is improved, but thermal resistance increases and heat evacuation deteriorates

Engineering Contradiction:

Improveelectrical insulationVSAvoidheat evacuation

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The heatsink is divided into multiple independent portions (first heatsink portion, second heatsink portion, third heatsink portion) that are electrically isolated from each other. Each portion is mounted on a corresponding conductive element, allowing heat to be evacuated directly through the conductive elements without passing through ceramic insulating layers, thus resolving the contradiction between electrical insulation and heat evacuation.

Inventive Principle:

Principle #1Segmentation

2Volume of moving object

If conductive elements are placed close together to reduce module size, then compactness is improved, but the risk of electrical arcs between high potential difference elements increases

Engineering Contradiction:

Improvemodule sizeVSAvoidelectrical arc risk

Core Design Contradiction:

Volume of moving objectVSReliability

Solution Approach 1:

The heatsink is segmented into multiple electrically isolated portions, each mounted on separate conductive elements. This segmentation allows the conductive elements to be positioned closer together for compactness while the isolated heatsink portions prevent electrical arcs by breaking the conductive path between high potential difference elements.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heatsink portions act as intermediary structures between the conductive elements. They provide electrical insulation through their material properties or coating, allowing close spacing of conductive elements while preventing electrical arcs by interrupting the potential discharge path.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Strength

If thick ceramic insulating layers are used to prevent electrical breakdown, then electrical insulation strength is improved, but thermal resistance increases and heat transfer efficiency deteriorates

Engineering Contradiction:

Improveelectrical insulation strengthVSAvoidheat transfer efficiency

Core Design Contradiction:

StrengthVSProductivity

Solution Approach 1:

Instead of using thick ceramic insulating layers, the invention segments the heatsink into multiple portions mounted on separate conductive elements. This eliminates the need for thick insulating layers between heat paths while maintaining electrical insulation through the segmented structure, thus improving heat transfer efficiency without compromising insulation strength.

Inventive Principle:

Principle #1Segmentation

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

Improves heat evacuation efficiency and reduces the risk of electrical arcs by minimizing thermal resistance and maintaining electrical insulation, ensuring reliable operation under high potential differences.

Implementation Method 1

enable the transfer of calories from each power component towards the corresponding portion of the heatsink throughout the corresponding conductive element

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 2

the first conductive element and the first portion of the heatsink being electrically insulated from the second element and from the second portion of the heatsink, via at least one electrical insulator

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Data Source

PatentUS12593686B2Power electronics module

Publication Date: 2026.03.31 SAFRAN ELECTRICAL & POWER

AI summary

Embodiments of the disclosure relate to a power electronics apparatus. The power electronics apparatus includes at least a first electrically conductive element and a second electrically conductive element. The elements are intended to be at a first electrical potential and at a second electrical potential, respectively. At least a first and second power electronics components are mounted on the first and second elements, respectively, a first portion and a second portion of a sink are mounted on the first conductive element and on the second conductive element, respectively, so as to permit the transfer of heat from each power component to the corresponding portion of the sink through the corresponding conductive element. An electrical insulator is present between each portion of the sink so as to prevent the risk of flashover between the two portions.