Spring Carrier Sawtooth Contour for Thermal and Mechanical Integration
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Solution Overview
Problem
Existing electronic devices in vehicle electronics face challenges in compactly integrating electronic components with variable electrical connections while ensuring electromagnetic compatibility and effective heat dissipation, often requiring complex shielding cables and multi-part housings with intricate assembly processes.
Innovation Solution
A compact electronic device design featuring a spring carrier with a sawtooth-shaped contour and a spring tensioner with a counter-contour, using a plastic spring for both thermal and mechanical contact, which allows for effective heat dissipation and secure mechanical retention without separate components, and angled contacting elements for flexible electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a housing is made in two parts connected by screws, then the electronic device can be assembled, but the assembly process becomes complex and the number of individual parts increases
Solution Approach 1:
The patent combines the first housing part and second housing part into a single integrated housing structure. The carrier plate with electrical connections is directly mounted within this unified housing, eliminating the need for separate housing parts and their connecting screws, thereby simplifying the assembly process and reducing the total number of parts.
Solution Approach 2:
The single housing structure serves multiple functions: it provides mechanical protection, acts as a mounting structure for the carrier plate, and functions as a heat dissipation path. By integrating these functions into one component, the patent eliminates the need for separate structural and fastening elements.
2Reliability
If cables with complex shielding measures are used, then electromagnetic compatibility requirements are met, but the device complexity and space requirements increase
Solution Approach 1:
The patent extracts the electrical connections from external cables and integrates them directly onto the carrier plate mounted within the housing. This eliminates the need for separate cables and their associated shielding measures, while maintaining electromagnetic compatibility through the compact, controlled arrangement of electrical connections on the carrier plate.
Solution Approach 2:
The carrier plate serves as an intermediary structure that provides direct electrical connections between components. By using the carrier plate as a mounting substrate with integrated electrical contacts, the patent eliminates the need for intermediate cables and their complex shielding requirements.
3Reliability
If separate components are used for thermal contact and mechanical retention, then each function is optimized, but the number of parts and assembly complexity increases
Solution Approach 1:
The patent combines the spring element and the mounting structure into a single integrated spring carrier component. This spring carrier simultaneously provides mechanical retention through its clamping action and thermal contact through its direct connection to the carrier plate and housing, eliminating the need for separate components for each function.
Solution Approach 2:
The spring carrier is designed as a multi-functional component that performs both mechanical retention (clamping the carrier plate) and thermal conduction (providing a heat path from the carrier plate to the housing). This universal component approach reduces the total number of parts while maintaining both thermal and mechanical performance.
4Reliability
If a compact arrangement of electrical connections is implemented, then electromagnetic compatibility is improved, but the adaptability to variable orientations is reduced
Solution Approach 1:
The patent employs a spring-based mounting system that provides flexible, adaptable connections. The spring carrier can accommodate variations in orientation and positioning while maintaining reliable electrical and thermal contact. This dynamic mounting approach allows the compact electrical connection arrangement to adapt to different installation orientations without compromising electromagnetic compatibility.
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 design achieves efficient heat dissipation, simplifies assembly, reduces the number of parts, and eliminates the need for separate connecting elements, enhancing electromagnetic compatibility and adaptability in limited installation spaces.
Implementation Method 1
The plastic spring offers the advantage of a component with two functions. First, the plastic spring provides thermal contact between the carrier plate, the spring holder, the spring tensioner, and the housing, ensuring effective heat dissipation through the housing
Implementation Method 2
Second, the spring force generated by the plastic spring provides a mechanical, friction-fit connection between the carrier plate, spring holder, and spring tensioner assembly within the housing
Data Source
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AI summary
The invention relates to an electronic device, in particular control device, having a cooling apparatus. The electronic device is arranged in a housing (1) and comprises an electronic circuit which is arranged on a support plate (2). In order to create advantageous structural conditions, it is proposed that a spring support (3) with at least one plastic spring (4), which makes mechanical and thermal contact with the support plate (2), is arranged on one side of the support plate (2), that side surfaces of the spring support (3) have a sawtooth-shaped contour (5), that a spring tensioner (6) with side faces which have a sawtooth-shaped mating contour (7) which forms a counterpart in relation to the sawtooth-shaped contour (5) of the side surfaces of the spring support is arranged on that side of the spring support (3) which is averted from the support plate, and that the support plate (2), the spring support (3) and the spring tensioner (6) are arranged on one another and in the housing in such a way that the support plate (2), the spring support (3) and the spring tensioner (6) are braced against one another and also against the housing (1) by means of the at least one plastic spring (4).