Wedge Element Mounting for Electrical Component Tolerance Compensation
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Solution Overview
Problem
Existing methods for mounting electrical components on base parts with inclined support surfaces face challenges in compensating mechanical tolerances while maintaining effective thermal links, often requiring complex and costly individual treatments or thermally conductive materials, and can impair heat transfer due to mechanical loading and multiple interfaces.
Innovation Solution
A method using a wedge element with a lateral force to adjust and fix its position on an inclined support surface, allowing for compensation of mechanical tolerances during assembly and maintaining a stable thermal link without additional thermally conductive pads, using screws for long-term fixation and ensuring efficient heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual treatment with copper sheets and thermally conductive films is used to compensate mechanical tolerances, then thermal link is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts the tolerance compensation function from the thermal interface materials (copper sheets and thermally conductive films) and transfers it to a dedicated wedge element. This allows the thermal interface materials to focus solely on thermal conduction while the wedge element handles mechanical alignment and gap compensation, simplifying the overall system design and reducing manufacturing complexity
Solution Approach 2:
The mounting system is segmented into distinct functional components: the wedge element for mechanical tolerance compensation, and separate thermally conductive materials for heat transfer. This segmentation allows each component to be optimized independently, with the wedge element made from materials like aluminum or magnesium that provide both structural support and thermal conduction pathways
2Reliability
If thermally conductive pipes (heat pipes) are used to compensate tolerances, then thermal link is improved, but manufacturing cost increases
Solution Approach 1:
The wedge element is implemented as a simple, inexpensive mechanical component that can be easily manufactured from common materials like aluminum or magnesium alloys. Unlike expensive heat pipes, the wedge element is a straightforward mechanical piece that provides both alignment and thermal conduction functions, significantly reducing component cost while maintaining effectiveness
Solution Approach 2:
The wedge element serves multiple functions simultaneously: it compensates for mechanical tolerances in lateral and vertical directions, provides structural support for the electrical component, and acts as a thermal conduction pathway. This multi-functionality eliminates the need for separate heat pipes and reduces the overall system complexity and cost
3Manufacturing precision
If two wedges with spring pressure are used to compensate tolerances, then mechanical tolerance compensation is achieved, but heat transfer is impaired by multiple interfaces and mechanical loading
Solution Approach 1:
The invention extracts the spring pressure mechanism from the heat transfer path and replaces it with a direct rigid or elastically supported wedge element. This eliminates the intermediate spring-wedge interface that impeded thermal conduction, allowing heat to flow directly through the wedge element and electrical component to the heat sink without encountering mechanical spring interfaces
Solution Approach 2:
The mounting system is segmented into distinct functional components: the wedge element for mechanical tolerance compensation, and separate thermally conductive materials for heat transfer. This segmentation allows each component to be optimized independently, with the wedge element made from materials like aluminum or magnesium that provide both structural support and thermal conduction pathways
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 method simplifies tolerance compensation, enhances thermal conductivity, and provides long-term stability with minimal mechanical strain, eliminating the need for thick thermally conductive pads and reducing costs, while maintaining effective heat transfer through a direct thermal bridge.
Implementation Method 1
A lateral force is now exerted on this wedge element. The force acts from the narrow side of the wedge element so that a force component causes the wedge element to move upwardly on the support surface until a second wedge surface of the wedge element disposed opposite the first wedge surface reaches a desired position
Implementation Method 2
The heat flow over the one wedge element is good and the fixing has long term stability with the most simple fastening means such as screws
Data Source
AI summary
A method of mounting an electrical component on a base part having an inclined support surface is provided, in which method a first wedge surface of a wedge element is arranged on the support surface and a lateral force is exerted on the wedge element so that the first wedge surface moves on the support surface until a second wedge surface of the wedge element remote from the support surface reaches a desired position, and wherein the electrical component is arranged on the second wedge surface. In this respect, a first fastening element of the wedge element is fixed to the base part and the lateral force is afterward no longer exerted.