Switch Clip Structure for Uniform Cooling in Power Converters
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Solution Overview
Problem
In power conversion devices, non-uniform contact between electronic components and the case leads to inefficient cooling, affecting the performance of DC-DC converters due to varying cooling efficiencies across multiple switches.
Innovation Solution
A power conversion device design featuring a clip with elastic parts that apply uniform pressure to multiple switches, ensuring consistent contact areas with the case, combined with a cooling channel and guide protrusions to enhance heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional fixing method is used for multiple switches, then the structure is simple, but the contact area between each switch and the case becomes non-uniform, reducing cooling efficiency
Solution Approach 1:
The elastic parts are designed to be deformable under compression, allowing them to dynamically adjust and apply uniform pressure to multiple switches. When the clip is screwed onto the case, the elastic parts compress and deform to conform to the switch positions, ensuring uniform contact area across all switches despite manufacturing tolerances or positional variations.
Solution Approach 2:
The elastic parts change their physical state from uncompressed to compressed, altering their shape and pressure distribution characteristics. This parameter change enables the transition from a non-uniform contact state to a uniform contact state, improving cooling efficiency without requiring complex adjustment mechanisms.
2Reliability
If uniform pressure is applied to all switches, then cooling efficiency is improved, but the clip structure becomes more complex with multiple elastic parts and through holes
Solution Approach 1:
The clip is segmented into a body part and multiple elastic parts, with the elastic parts distributed between adjacent switches. This segmentation allows each elastic part to independently apply pressure to its corresponding switch, ensuring uniform contact area. The body part includes through holes for screws, enabling simple fixation to the case without complex adjustment mechanisms.
Solution Approach 2:
The elastic parts serve multiple functions: they provide mechanical pressure to ensure uniform contact area, act as a cushioning element to accommodate positional variations, and simplify the overall fixing structure by eliminating the need for separate adjustment mechanisms for each switch.
3Temperature
If the contact area between switches and case is non-uniform, then the structure is simpler, but heat dissipation performance deteriorates due to varying cooling efficiency
Solution Approach 1:
The elastic parts are strategically positioned between adjacent switches to provide localized pressure where needed. Each elastic part ensures uniform contact area for its corresponding switch, addressing the specific cooling requirement of each component without requiring uniform precision across the entire assembly.
Solution Approach 2:
The elastic parts are designed to compress beforehand when the clip is installed, creating a cushioning effect that pre-compensates for any positional variations or manufacturing tolerances. This beforehand cushioning ensures that uniform pressure is applied to all switches from the start, guaranteeing consistent contact area and optimal heat dissipation performance.
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
The uniform pressure distribution across switches improves heat dissipation, maintaining consistent cooling efficiency and enhancing the overall performance of the power conversion device.
Implementation Method 1
elastic parts which extend from the body part and are for pressing the plurality of switches to the case
Implementation Method 2
a cooling channel disposed on the other surface of the case; and a coolant inlet and a coolant outlet, which are connected to the cooling channel
Data Source
AI summary
Disclosed is a power conversion device comprising: a case; a switching unit comprising a plurality of switches which are disposed on one side of the case; a transformer disposed on one side of the case; and a clip for fixing the plurality of switches. The clip comprises: a body part which is fixed to the case; and elastic parts which extend from the body part and are for pressing the plurality of switches to the case. The body part comprises a plurality of first through holes into which screws are coupled. And the first through holes are disposed between two adjacent elastic parts.