Stacked Electrical Device Cooling and Conductor Arrangement
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Solution Overview
Problem
Existing power converter designs for industrial motors are inefficient in space utilization due to the large space requirements of electrical conductors, which can lead to increased area consumption and potential short circuits.
Innovation Solution
The design arranges switching modules and cooling devices with conductors stacked vertically, using insulating intermediate layers and a fixing means that matches the thermal expansion of the housing material, along with elastic elements to manage pressure and separate high-current and signal conductors, allowing for efficient space use and reduced leakage currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If electrical conductors are arranged in a conventional layout, then electrical connections are established, but the installation space required is large
Solution Approach 1:
The patent transitions from a planar arrangement of electrical conductors to a three-dimensional stacked configuration where conductors are arranged vertically above switching element modules. This dimensional change allows conductors to be positioned in the vertical dimension rather than requiring extensive horizontal space, thereby reducing the overall footprint while maintaining all necessary electrical connections.
Solution Approach 2:
The patent implements a nested structure where conductors are positioned within the vertical space above switching element modules, and insulating layers are nested between conductors. This nesting approach allows multiple components to occupy overlapping vertical spaces, maximizing space utilization and minimizing the horizontal installation area.
2Area of stationary object
If conductors are placed close together to save space, then space is reduced, but the risk of short circuits and leakage currents increases
Solution Approach 1:
The patent introduces insulating layers as intermediary elements positioned between adjacent conductors in the stacked arrangement. These insulating layers act as mediators that prevent direct electrical contact between conductors while allowing them to remain in close proximity vertically, thus enabling space reduction without compromising electrical isolation or increasing short circuit risk.
3Stability of the object's composition
If fixing means is used to secure conductors, then mechanical stability is improved, but electrical isolation from ground becomes difficult
Solution Approach 1:
The patent positions insulating layers between the conductors and the fixing means (housing or cooling device). These insulating layers serve as intermediaries that allow the fixing means to provide mechanical stability and secure the conductors in place while simultaneously maintaining electrical isolation, preventing unwanted electrical connections to ground.
4Adaptability or versatility
If different materials are used for fixing element and housing, then assembly flexibility is improved, but thermal stresses increase due to different expansion coefficients
Solution Approach 1:
The patent specifies that the fixing element be made of the same material as the housing or cooling device. This material homogeneity ensures that both components have identical thermal expansion coefficients, eliminating differential thermal stresses that would arise from material mismatches during temperature variations, while still allowing for flexible assembly through appropriate design of the fixing element geometry.
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 significantly reduces space requirements, prevents short circuits, and enhances thermal management, making it suitable for applications with limited installation space, such as motor vehicles.
Implementation Method 1
the switching element module (40), which can be cooled by a cooling device (110) and rests at least indirectly on it
Implementation Method 2
the at least one conductor (64) is electrically separated from the fixing means (55) by at least one insulating intermediate layer (61)
Implementation Method 3
an elastic module is provided between the fixing device and the switching device module
Data Source
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AI summary
The invention concerns an electrical device, particularly for driving a motor- and/or generator-operable electrical machine (280), comprising at least one switching means module (40), preferably for inverting and/or rectifying electrical currents, the switching means module (40) being able to cooled by a cooling device (110) and resting at least indirectly thereupon. A fixing means (55), at least one conductor (64), and the switching means module (40) and cooling device (110) are arranged one above the other.