Stepped Heat Radiation Member for Power Tool Controller
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Solution Overview
Problem
Existing electric power tools face challenges in achieving sufficient heat radiation while reducing the size and thickness of the controller and heat radiation member, leading to decreased heat exchange efficiency.
Innovation Solution
The controller incorporates a heat radiation member with varying distances from the circuit board surface, corresponding to the protrusion amounts of electric components, and includes a conductor pattern for direct heat exchange, along with an insulating sheet for enhanced thermal conductivity and electrical insulation, allowing for effective heat dissipation while maintaining a compact design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the heat radiation member is reduced in size and thickness, then the controller size and thickness are reduced, but the heat exchange efficiency deteriorates
Solution Approach 1:
The patent introduces a third dimension (depth/distance from circuit board) to the heat radiation member design. By creating a stepped structure with multiple levels at different distances from the circuit board, the solution transforms a two-dimensional surface problem into a three-dimensional space utilization problem, allowing sufficient heat exchange volume within a reduced overall thickness.
Solution Approach 2:
The heat radiation member is divided into multiple stepped levels, each serving as an independent heat exchange surface. This segmentation allows different portions of the circuit board to have optimized heat radiation distances, improving overall heat exchange efficiency while maintaining a compact form factor.
2Loss of energy
If the distance between heat radiation member and circuit board is increased, then heat radiation effect is improved, but the controller thickness increases
Solution Approach 1:
Different regions of the heat radiation member have different distances from the circuit board surface, optimized according to the local heat generation characteristics of underlying components. High-heat-generation areas have larger gaps for better heat radiation, while low-heat areas have smaller gaps, maintaining compact overall thickness.
Solution Approach 2:
The stepped structure creates dynamic variation in the gap distance between the heat radiation member and circuit board. This dynamic distance adjustment allows optimization of heat exchange at each level without requiring uniform increase in overall thickness.
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 enhances heat radiation efficiency, allowing for effective heat exchange between the electric components and the heat radiation member, thereby maintaining performance while reducing the size and thickness of the controller and heat radiation member.
Implementation Method 1
a heat radiation member which radiates heat of the electric components
Implementation Method 2
heat is exchanged between the first facing part and the switching devices
Data Source
AI summary
In an electric power tool which houses a motor and a controller for controlling drive of the motor, the controller has a circuit board on which electric components are mounted and a heat radiation member which radiates heat of the electric components. The heat radiation member has a facing part which faces the circuit board in parallel to a board surface of the circuit board. The facing part is provided with steps by which a distance between the facing part and the board surface of the circuit board varies. Furthermore, the facing part of the heat radiation member is provided with a first facing part in which a relative distance with respect to the board surface of the circuit board is reduced.