DE102021214462A1 - control unit family - Google Patents

Abstract

The starting point is a control unit family of a control unit platform with at least two, three, four or more variants of control units of different performance classes. The variants of the control device have at least a first and second housing element, which form a cavity in the assembled state. An equipped circuit carrier of a respective performance class, which is to be cooled, is then accommodated within this cavity. The circuit carrier is at least partially in thermal contact with one of its two main sides, at least indirectly, with an inner surface of the second housing element facing this one main side. Furthermore, on an outer surface of the second housing element facing away from this one main side of the circuit carrier, a heat dissipation area is formed on an area adjacent to the outer surface. The control unit family includes at least two, three or more different power class ranges, each with at least one power class falling in each power class range of at least one variant of the control unit. Here, variants of the control unit from two different performance class areas differ in their heat emission area in that the cooling capacity of the respective heat emission area is adapted to the respective defined performance class area. This is achieved by extending the heat dissipation range, starting from a lowest specified power class range to a highest specified power class range of the control unit family with an increasingly higher power class range, in each case by an additional new class of heat dissipation elements. The heat dissipation capacity of the heat dissipation area of the respective performance class area is increased by the new class of heat dissipation elements compared to previous lower performance class areas

Description

The invention relates to a control unit family and a method for designing the control unit family according to the preamble of the independent claims.

State of the art

Electrical devices include electrical and/or electrical components which generate heat loss during operation. As a result of the heat loss, a time-stable or a time-variable operating temperature for the electrical device may arise depending on the operating mode. However, if the operating temperature exceeds critical temperature values, this can lead to malfunctions within the electrical device. In particular, electrical and/or electronic components can also be damaged to such an extent that operation of the electrical device is no longer possible. To ensure safety, electrical devices are designed for a safe operating temperature using defined heat dissipation concepts. Depending on the performance class of the electrical device, the cooling concepts can differ greatly from one another, so that different implementations of electrical devices must always be provided depending on the performance class.

In the motor vehicle sector in particular, the number of computer-aided systems is increasing, particularly in the form of upgraded control devices or in the form of central vehicle computer units (VCU).

The increasing computing power is accompanied by an increasing thermal load on the electrical and/or electronic components. In this regard, appropriate cooling concepts are developed and/or adapted. Due to increasingly shorter product development cycles and increasing product complexity, it is often problematic that at the beginning of new product development, the final specification for the new products has not yet been determined or is not yet known. This includes properties such as installation space, the ambient temperature, but also the thermal power loss. In addition, product development is increasingly aimed at a common technology platform, from which various product variants to cover various customer interests are taken into account and provided for through adjustments, changes and/or extensions. Despite the same technological basis, product variants of the same technology platform then differ greatly from one another, since simple scaling is difficult to implement due to the variant-related differences. Subsequent variants may require a new implementation because, for example, an existing heat dissipation concept for a higher performance class of the subsequent variant is not operationally reliable.

From the disclosure document DE10 2015 212 721 A1 a cooling device for cooling a power semiconductor is known. The cooling device comprises a closed cavity through which a cooling liquid flows via an inlet and an outlet. To increase heat dissipation, the cooling device has pins protruding into the cavity from an inner surface delimiting the cavity. The power semiconductor is arranged on an outer surface of the cooling device facing away from the journal.

The disclosure document DE 10 2014 106 134 A1 shows a cooling system for a molded module. The cooling system includes a multi-part cooling housing with an inlet and an outlet for a cooling medium. A molded module is received within a cavity formed by the cooling shroud. This has cooling plates, which are formed on the outside of the module as areas exposed by the mold. One of these module sides with the cooling plates is covered by a cover as a housing part, forming a liquid cavity. This is covered by the cover from the rest of the module. In addition, the cover includes the inlet and outlet for the cooling medium. In cooling operation, the cooling plates on one side of the module are cooled by the cooling liquid flowing through them within the liquid cavity. The multi-part housing can be made of metal or a plastic material.

The disclosure document DE 199 11 205 A1 discloses a cooling device for electronic components. Inside a cavity formed by two housing elements of the cooling device, a corrugated metal sheet is arranged as cooling ribs to increase a heat transfer surface, which rests on an elastic element and is thereby pressed against one of the housing elements under pretension. A cooling liquid flows through the cavity via an inlet and an outlet. The elastic element is in abutting contact with one of the metal housing elements. The other housing element, on the other hand, is made of plastic. This has a recess on a side facing away from the cooling fins, in which the electronic components are accommodated.

Disclosure of Invention

Advantages

The invention is based on the object of making it possible to create or expand variants within a control device family of the same control device platform in a simple and cost-effective manner.

This object is achieved by a control device family and a method for designing the control device family according to the independent claims.

The starting point is a control unit family of a control unit platform with at least two, three, four or more variants of control units of different performance classes. A required performance class is achieved in particular and essentially by corresponding power components provided in the respective control device. A higher performance class is usually associated with higher heat development during operation. In this respect, a higher performance class is also associated with a need for greater heat dissipation for operation. The variants of the control unit have at least a first and a second housing element, which form a cavity when installed. An equipped circuit carrier of a respective performance class, which is to be cooled, is then accommodated within this cavity. The circuit carrier is at least partially in thermal contact with one of its two main sides, at least indirectly, with an inner surface of the second housing element facing this one main side. For example, a TIM material (Thermal Interface Material) is arranged in each case directly adjacent between the second housing element and the circuit carrier. The TIM material can be coupled directly to a circuit carrier side or directly to an electronic and/or electrical component to be cooled, for example a power semiconductor, in particular a chip. A heat flow or heat exchange with the second housing element is made possible by means of the thermal system contact. Furthermore, on an outer surface of the second housing element facing away from this one main side of the circuit carrier, a heat dissipation area is formed on an area adjacent to the outer surface. In this way, thermal energy can be dissipated from the circuit carrier. The control unit family includes at least two, three or more different power class ranges, each with at least one power class falling in each power class range of at least one variant of the control unit. The performance class ranges can be defined application-specifically. There is preferably no overlapping of the same performance class values between the performance class ranges. It is possible that two, several or all defined performance class areas with their lowest and highest included performance classes are not directly connected. Accordingly, there can be a gap between two next-neighboring specified power class ranges of power classes that are otherwise not included in any specified power class range. The gap can be partially or fully covered at any time by specifying at least one new corresponding power class range. Here, variants of the control unit from two different performance class areas differ in their heat emission area in that the cooling capacity of the respective heat emission area is adapted to the respective defined performance class area. This is achieved by extending the heat dissipation range, starting from a lowest specified power class range to a highest specified power class range of the control unit family with an increasingly higher power class range, in each case by an additional new class of heat dissipation elements. The heat dissipation capacity of the heat dissipation area of the respective performance class area is increased by the new class of heat dissipation elements compared to previous lower performance class areas. Such a class comprises precisely one heat-emitting element or a plurality of heat-emitting elements which are identical or at least present in the same state of aggregation and are geometrically similar in design. Within a class, the included heat dissipation elements follow the same heat dissipation principle, for example thermal conduction, thermal radiation, natural or forced cooling and/or evaporative cooling. Classes of heat dissipation elements preferably differ in particular by their different power densities, with a new class of heat dissipation elements at a next higher specified power class range increasing by a factor of x>=2, in particular by a factor of x>=5, preferably by a factor of x>=10 , For example, the power density is higher by a factor of x>=20 than all classes of heat dissipation elements included in the previously specified power class range. More preferably, in addition or as an alternative, the classes can be differentiated by at least one other underlying heat dissipation principle. Alternatively, different classes can follow the same heat dissipation principle(s), but have heat dissipation elements in different physical states, different materials and/or with a different geometry, with the previously mentioned distinction in their power densities.

In this way, simple variant formation of control units is advantageously made possible within the same control unit platform, in which a respective scaling of the heat dissipation capacity is implemented as a function of the specified power class range for the corresponding variant of the control unit. In this way, the variant can be operated safely in a defined temperature range. Since the heat dissipation capacity is clearly included for a performance class area, a heat dissipation solution that is as cost-effective as possible can be implemented, which only has to meet the specification within the assigned performance class area, despite possibly having many variants. This straightens out or simplifies the complexity of many specification requirements for all variants at the level of the performance class areas. Furthermore, when specifying a new variant, for example due to new customer requirements, or generally when specifying customer specifications at short notice, by assigning the variant to a correspondingly falling power class range, an existing heat dissipation solution for the power class range within the control unit family can be used. Advantageously, this means that test specifications that are intended to rule out any risk that may exist in new heat dissipation concepts can be omitted. Likewise, new performance class ranges for variants can be developed or defined in a simple manner. The new performance class range can already be based on the experiences of the heat dissipation solutions from the previous performance class ranges. In particular, on the basis of the expansion of the heat dissipation solutions by a new class of heat dissipation elements for the next higher performance class range, the respective dissipation capacity of the known classes of heat dissipation elements that were already included can be used to advantage. This increases efficiency and reduces risk when defining new power class ranges.

Advantageous developments and improvements of the method according to the invention are possible as a result of the measures listed in the dependent claims.

In an advantageous embodiment of the control device family, the additional new class of heat dissipation elements of a next higher performance class range is not included in all preceding lower performance class ranges. Since the power densities of the newly added classes of heat dissipation elements differ many times over, a number of power class ranges can be defined which have different value ranges for the power classes covered. This means, for example, that performance class ranges can also be defined that do not build on each other in a linear manner, but instead show larger jumps in performance. In this way, control unit families can also be implemented that cover a very wide range of performance classes, in particular over several powers of ten.

In a particularly favorable embodiment of the control device family, the second housing element is metallic, in particular made of aluminum or an aluminum alloy. Due to the metallic design, a basic cooling capacity can be raised to a higher level with simple means right from the start. This means that generally higher performance class ranges can be built up.

In a preferred embodiment of the control device family, the second housing element is an injection-molded part and the outer surface of the second housing element is designed as an at least essentially or completely mold surface on the injection-molding tool side. In this case, the molding surface comprises, at least in regions, a one-piece molding of the heat-dissipating elements of the respective class/classes of heat-dissipating elements contained in the performance class area. Additionally or alternatively, the molding surface also includes a molding of at least one interface for connecting partial elements of the respective class/classes of heat dissipation elements contained in the performance class area. In this case, the interface can in particular comprise fastening elements, sealing surfaces, receiving elements or something else, in order to form the heat dissipation function of this class of heat dissipation elements in an active combination together with the sub-element mentioned. In particular, the molding surface that encompasses the heating elements and/or interfaces of heating elements is designed in such a way that it can be completely shaped by demolding only one injection molding tool element in a demolding direction. Advantageously, the formation and adaptation of variations to the respective performance class range is essentially reduced to the different impression surfaces to be carried out. This provides a cost-effective technical option, for example with interchangeable inserts, pin inserts and/or slides, to mold the required molding surface for a specified performance class range in a defined manner only within one of the injection molding tool elements. More preferably, each new class of heat dissipation elements occupies a free local surface area of the formation surface, which is from the class/classes of a previous performance class area is not occupied. In this way, the injection molding tool element associated with the molding surface can be designed in a particularly simple manner.

An embodiment of the control device family is particularly preferred in which two or more variants of the control device belonging to the same performance class range have an identically designed heat dissipation area and/or an identically designed second housing element. A particularly cost-effective control device family can thus be implemented, in particular by then repeated application of the heat dissipation solution of a power class range to a possibly large number of variants of the control device contained in the power class range.

In a further development of the control unit family, the heat dissipation area in a power class range is formed exclusively or essentially by a flat outer surface of the second housing element as a first class of heat dissipation elements. In particular, such a structurally existing heat emission area is formed in a first performance class range of the control unit family, i.e. within variants of the control unit in the lowest performance class range of the control unit family. At least areas of the outer surface where there is a local thermal coupling to the circuit carrier and/or to an electrical and/or electronic component of the circuit carrier can deviate from the plane. Indentations and/or protuberances in the direction of the existing gap can be provided to bridge gap distances to the circuit carrier and/or the electrical and/or electronic component. With an at least essentially flat shaping surface, variants of the control device in the lowest performance class range can be kept very simple and compact. Furthermore, a flat shaping surface offers a favorable starting point for expanding the heat dissipation area with new additional classes of heat dissipation elements for the next higher performance class range.

It is optionally possible for the control device family designed in this way that at least two variants of control devices of different performance classes within the first performance class range differ in the surface area of the outer surface of the second housing element, with the surface area increasing as the performance class increases. In this way, if required, an additional, differentiated adjustment option between performance classes within the same performance class range can be provided very easily. This makes particular sense if, within a performance class, the heat dissipation capacity of the respective heat emission area of the variants with the highest performance classes is not yet fully sufficient or if an additional safety buffer is to be added.

In an advantageous further developed embodiment of the control unit family, in a further power class range, in particular a larger second power class range of the control unit family immediately following the first, the heat dissipation area is formed or expanded by a heat dissipation structure protruding from the outer surface of the second housing element as a second class of heat dissipation elements. The heat dissipation structure has, in particular, pegs, rib webs or other shaped elevations protruding from the outer surface, in particular in the form of a pattern arrangement. For example, the heat dissipation structures can be formed as pin fins. Advantageously, heat dissipation structures of this type can be very easily reproduced in a wide variety of forms via inserts that can be used or exchanged within one injection molding tool element. Overall, this type of heat dissipation structure allows a multiplication of the heat-emitting surfaces within the heat-emitting area, in particular with regard to the essentially planar outer surface of a preceding performance class area as the corresponding heat-emitting area.

Optionally, it is possible for the control device family designed in this way that at least two variants of control devices of different performance classes within the second performance class range differ in the structure size of the respective cooling structure. The size of the structure increases with an increasing performance class in relation to the number of pegs, rib webs and/or other shaped elevations, for example pin fins, protruding from the outer surface and/or their size. Similar to the first performance class area, this option makes sense if within the second performance class area the cooling capacity of the respective heat emission area of the variants with the highest performance classes is not yet fully sufficient or should be increased with an additional safety buffer.

In an advantageous further developed embodiment of the control device family, in a further power class range, in particular a larger third power class range immediately following the first and/or the second, the heat dissipation range is provided by a surface of the second housing element is directly formed or expanded as a third class of heat dissipation elements. In this case, areas or the entire outer surface of the second housing element forms a partial surface of the cooling channel. Advantageously, the known design of the heat emission range from previous performance class ranges can continue to be used essentially identically. By providing a cooling fluid, for example cooling water, which also flows through the cooling channel over this cooling area, its cooling capacity can in turn be increased many times over for the next higher performance class range. The heat dissipation duct is preferably formed from a duct housing that is shaped like a channel over at least one section, in particular as a plastic injection molded part, with the duct housing being arranged in the region of its channel-like section from its open side in a sealing manner on the outer surface of the second housing element, forming a heat dissipation duct that is closed on all sides. The heat dissipation channel is materially or mechanically connected to the second housing element, as a permanently fixed connection or as a detachable connection. For the connection and/or as a sealing surface, a correspondingly shaped interface is formed on the tool side in the outer surface. The sealing surface runs complementary to the open side of the cooling channel. Furthermore, a connecting element can also be formed, for example, which can be operatively connected to a corresponding connecting element arranged in a complementary manner on the heat dissipation duct in order to form the connection. The heat dissipation duct thus generally forms a sub-element of the added new class of heat dissipation elements. More preferably, the heat dissipation channel has an inlet connector and an outlet connector for the cooling fluid, with both connectors then being formed in particular in one piece within the channel housing. In a simple form, without the heat dissipation channel, the design of the heat dissipation area can also be used unchanged for a variant of a preceding power range, for example the second power range described.

Optionally, it is possible for the control device family designed in this way that at least two variants of control devices of different performance classes within the third performance class range differ in the flow cross section of the respective cooling duct, the flow cross section increasing with increasing performance class.

In an advantageous further developed embodiment of the control device family, in a further performance class area, in particular a larger fourth performance class area of the control device family immediately following the first, second and third, the heat dissipation area is provided by a cooling device arranged on the outer surface of the second housing element according to the principle of evaporative cooling, for example a heat pipe or a vapor chamber, designed or expanded as a fourth class of heat dissipation elements. Alternatively, said cooling device is partially or fully embedded within the cast material of the second housing member. The heat pipe or vapor chamber can be cast as an insert in the already mentioned injection molding tool element during an injection molding process in the area of the outer surface. Alternatively, the cooling device can also be embedded within the duct housing, in particular having a surface which enables direct contact with the fluid flowing through. Advantageously, a heat dissipation area designed in this way can in turn be increased many times over in terms of its heat dissipation capacity compared to variants in previous performance class ranges.

1. a) Festlegen von zwei, drei oder mehr voneinander unterschiedlichen Leistungsklassenbereiche für die Steuergerätefamilie, wobei jedem Leistungsklassenbereich zumindest ein Steuergerät mit einer in den Leistungsklassenbereich fallender Leistungsklasse zugeordnet wird,
2. b) Festlegen von Klassen von Wärmeabgabeelemente, wobei ausgehend von einem niedrigsten Leistungsklassenbereich bis zu einem höchsten Leistungsklassenbereich zur Anpassung des jeweiligen Entwärmungsbereiches eines Steuergerätes innerhalb eines Leistungsklassenbereichs an den Leistungsklassenbereich jedem zunehmend höheren Leistungsklassenbereich jeweils eine zusätzliche neue Klasse von Wärmeabgabeelementen zugeordnet wird, durch welche das Entwärmungsvermögen des Wärmeabgabebereichs des jeweiligen Leistungsklassenbereiches gegenüber vorausgehenden niedrigeren Leistungsklassenbereichen erhöht wird,
3. c) Ausbilden jeweils zumindest einer Variante des Steuergerätes innerhalb der zwei, drei oder mehr festgelegten Leistungsklassenbereiche, indem der jeweilige Entwärmungsbereich mit der/den jeweils dem Leistungsklassenbereich zugeordneten Klasse/Klassen von Wärmeabgabeelemente ausgebildet bzw. erweitert wird.

The invention also leads to a method for forming a control device family of a control device platform according to at least one of the previously described embodiments. The process includes the following process steps:

1. a) Specification of two, three or more different power class ranges for the control unit family, with each power class range being assigned at least one control unit with a power class that falls within the power class range,
2. b) Defining classes of heat dissipation elements, starting from a lowest performance class range up to a highest performance class range for adapting the respective heat dissipation range of a control unit within a performance class range to the performance class range, each increasingly higher performance class range is assigned an additional new class of heat dissipation elements, through which the heat dissipation capacity the heat emission range of the respective power class range is increased compared to previous lower power class ranges,
3. c) Forming in each case at least one variant of the control device within the two, three or more specified performance class ranges by the respective heat dissipation range is formed or expanded with the class/classes of heat dissipation elements assigned to the performance class range.

In an advantageous embodiment of the method, the respective heat dissipation area is formed at least in regions by an injection molding tool, with the injection molding tool in the area of the heat dissipation area being designed to be adaptable in terms of its molding geometry, so that depending on the performance class area in method step c), the injection molding tool is used to mold the parts assigned to the respective performance class area Class/classes of heat dissipation elements and/or for the molding of an interface for connecting sub-elements of the class/classes of heat dissipation elements assigned to the respective performance class range is adapted.

The process has the same advantages as those mentioned above for the control unit family.

character list

• 1: ein Ausführungsbeispiel einer Variante eines Steuergerätes einer Leistungsklasse innerhalb eines ersten festgelegten Leistungsklassenbereichs einer Steuergerätefamilie in einer geschnittenen Seitenansicht,
• 2: ein Ausführungsbeispiel einer Variante eines Steuergerätes einer Leistungsklasse innerhalb eines zweiten festgelegten Leistungsklassenbereichs einer Steuergerätefamilie in einer geschnittenen Seitenansicht,
• 3a: ein Ausführungsbeispiel einer ersten Variante eines Steuergerätes einer Leistungsklasse innerhalb eines dritten Leistungsklassenbereichs einer Steuergerätefamilie in einer geschnittenen Seitenansicht,
• 3b: ein Ausführungsbeispiel einer zweiten Variante eines Steuergerätes einer höheren Leistungsklasse als die erste Variante aus der 3a, aber immer noch innerhalb des dritten Leistungsklassenbereichs der Steuergerätefamilie in einer geschnittenen Seitenansicht,
• 3c: die erste Variante oder zweite Variante aus den 3a oder 3b mit zusätzlich ausgebildeten Vertiefungen im Gehäuse,
• 4: ein Ausführungsbeispiel einer Variante eines Steuergerätes einer Leistungsklasse innerhalb eines vierten festgelegten Leistungsklassenbereichs einer Steuergerätefamilie in einer geschnittenen Seitenansicht.

Further advantages, features and details of the invention result from the following description of preferred exemplary embodiments and from the drawing. This shows in:

• 1 : an exemplary embodiment of a variant of a control unit of a performance class within a first specified performance class range of a control unit family in a sectional side view,
• 2 : an exemplary embodiment of a variant of a control unit of a performance class within a second defined performance class range of a control unit family in a sectional side view,
• 3a : an exemplary embodiment of a first variant of a control unit of a performance class within a third performance class range of a control unit family in a sectional side view,
• 3b : an embodiment of a second variant of a control unit of a higher performance class than the first variant from the 3a , but still within the third performance class range of the control unit family in a sectional side view,
• 3c : the first variant or second variant from the 3a or 3b with additional recesses in the housing,
• 4 1: an exemplary embodiment of a variant of a control device of a performance class within a fourth specified performance class range of a control device family in a sectional side view.

Embodiments of the invention

In the figures, functionally identical components are each identified by the same reference symbols.

The 1 , 2 , 3a , 3b , 3c and 4 show different variants 11, 21, 31, 32, 41 of a control unit 100 of an exemplary control unit family 1234, in particular of a motor vehicle powered by a motor. Each of these variants 11, 21, 31, 32, 41 is based on the same control unit platform. A distinction is particularly evident in the respective performance class 100.1, 100.2, 100.3, 100.4, 100.x of the variants 11, 21, 31, 32, 41, for which the individual variant 11, 21, 31, 32, 41 is then specifically used can be brought. For example, the performance classes 100.1, 100.2, 100.3, 100.4, 100.x form a series of ascending performance classes. For the 1234 family of control units, two, three or more performance class ranges 1, 2, 3, 4 that differ from one another are defined, for example four. The specified performance class ranges 1, 2, 3, 4 each define a size range for a lowest and a highest included performance class 100.1, 100.2, 100.3, 100.4, 100.x. The size range of all performance class areas 1, 2, 3, 4 is the same in each case, but can also be different in size for at least two performance class areas 1, 2, 3, 4. In the present exemplary control unit family 1234, the exemplary power class ranges 1, 2, 3, 4 with their respective size ranges are adjacent to one another in terms of value. Alternatively, there can also be gaps between at least two performance class ranges 1, 2, 3, 4, so that certain values of performance classes 100.1, 100.2, 100.3, 100.4, 100.x are not taken into account for a control unit family 1234, ie these are not considered variants of a Control unit 100 contains. A defined power class range 1, 2, 3, 4 comprises at least one variant 11, 21, 31, 32, 41 of a power class 100.1, 100.2, 100.3, 100.4, 100.x falling in value in this power class range 1, 2, 3, 4. Just for illustration, the control device family 1234 has a variant 11 of the control device 100 with the performance class 100.1 according to a first performance class range 1 1 on, in a second performance class area 2, a variant 21 of the control device 100 with the performance class 100.2 according to 2 , In a third performance class area 3 two variants 31, 32 of control units 100 with the performance classes 100.3 and 100.x according to 3a and 3b as well as in a fourth performance class area 4 a variant 41 of the control unit 100 with the performance class 100.4 according to the 4 . Deviating from this, a different number of performance class ranges can be defined in other control unit families, with a different number of performance classes and with other value sizes of performance classes, which are then each assigned to a defined performance class range.

All variants 11, 21, 31, 32, 41 of the control unit 100 of a control unit family 1234 have according to the 1 , 2 , 3a , 3b , 3c , 4 at least one housing 50, which is designed in particular in several parts. For example, a first housing element 51 and a second housing element 52 enclose a cavity 55 in the assembled state. The housing 50, but at least the second housing element 52, is preferably made of aluminum or an aluminum alloy. A circuit carrier 60 that is equipped with components to be cooled and is to be cooled is accommodated in the housing 50 . The circuit carrier 60 has two main sides 61, 62, which each face inside the cavity 55 facing inner surfaces 51.1 and 52.1. A thermal system contact A is established at least indirectly between at least one of these inner surfaces 51.1, 52.1 and one of these main sides 61, 62. For example, a TIM material (Thermal Interface Material) 59 is arranged between the bottom surface 52.1 and the main side 62 facing it or at least one electrical and/or electronic component 65 arranged on the main side 62 to form the thermal system contact A. This creates a flow of heat W of the assembled circuit carrier 60 or the one electrical and / or electronic component 65 on the second housing element 52 allows. On the second housing element 52, on an outer surface 52.2 facing away from the housing bottom 52.1, a heat dissipation area 54 is formed, from which the heat is dissipated further. The heat dissipation area 54 is determined by at least one specific class of heat dissipation elements 54.1, 54.2, 52.3, 54.4, through which the heat dissipation capacity of the heat dissipation area 54 is maximally defined. Each of the classes of heat dissipation elements 54.1, 54.2, 52.3, 54.4 differs from one another in particular by their power density, with power densities of the next neighboring classes 54.1, 54.2, 52.3, 54.4 with increasing power density in terms of value being able to differ many times over, in particular by a factor x> =2, in particular by a factor of x>=5, preferably by a factor of x>=10, for example by a factor of x>=20.

Variants 11, 21, 31, 32, 41 of the control unit 100 from two different performance class areas 1, 2, 3, 4 differ in their respective trained heat emission area 54. The distinction results from the fact that the cooling capacity of the respective heat emission area 54 to the for the variant 11, 21, 31, 32, 41 assigned power class range 1, 2, 3, 4 is adapted. With an increasingly higher performance class range 1, 2, 3, 4, each variant 11, 21, 31, 32, 41 that falls in terms of value is expanded by an additional new class of heat dissipation elements 54.1, 54.2, 52.3, 54.4, which increase the heat dissipation capacity of the heat dissipation area 54 of the respective power class range 1, 2, 3, 4 compared to previous lower power class ranges 1, 2, 3, 4 increased, in particular by the multiple mentioned. In the ones explained below 1 , 2 , 3a , 3b , 3c , 4 shows the differences in the exemplary control unit family 1234.

The 1 shows a variant 11 of the control device 100 with a performance class 100.1. Variant 11 is assigned to a first specified performance class range 1 of the 1234 control unit family. The first performance class range 1 is, for example, also the lowest defined performance class range 1. The heat dissipation area 54 is designed here exclusively or essentially by a planar outer surface 52.2 of the second housing element 52. The heat can pass through the wall of the second housing element 52 to the flat outer surface 52.2 via heat conduction from the thermal system contact A. From there, the heat can be further dissipated by convection in the ambient air. The flat outer surface thus forms a first class of heat dissipation elements 54.1 for this variant 11 and all possible other conceivable variants within the first performance class range 1. At least a second variant within the first performance class range 1 with a higher performance class than the illustrated variant 11 can still be enlarged in terms of the effective planar outer surface 52.2.

The 2 shows a variant 21 of the control device 100 with a performance class 100.2. Variant 21 is assigned to a second specified performance class range 2 of the 1234 control unit family. The second performance class range 2, for example, directly adjoins the lowest defined performance class range 1 with corresponding variants of higher performance classes 100.2. In addition to the flat outer surface 52.2 of the second housing element 52, the heat dissipation area 54 is compared to 1 with an additional cooling structure 53.2 extended. The heat dissipation structure 53.2 is formed, for example, from protruding ribs and/or pins, for example in the form of pin fins. By means of this heat dissipation structure 53.2, the heat dissipation capacity of the heat dissipation area 54 is also compared to 1 significantly increased, in particular by a multiple. The heat can now also be dissipated via the outer surface of the heat dissipation structure 53.2 by means of radiation. The heat dissipation structure 53.2 thus forms a new, second class of heat dissipation elements 54.2 for this variant 21 and all possible other conceivable variants within the second performance class range 2. At least one second variant within the second performance class range 2 with a higher performance class than the variant 21 shown can still be enlarged in terms of the structure size of the heat dissipation structure 53.2. This can, for example, relate to the number of pins and/or their height or cross-section.

The 3a shows a first variant 31 of control unit 100 with a performance class 100.3. Variant 31 is assigned to a third defined performance class range 3 of the 1234 control unit family. The third performance class range 3, for example, directly adjoins the aforementioned second performance class range 2 with corresponding variants of even higher performance classes 100.3. In addition to the flat outer surface 52.2 of the second housing element 52 and the heat dissipation structure 53.2, the heat dissipation area 54 is compared to the versions of FIG 1 and 2 with an additional cooling channel 53.3a that can flow through the outer surface 52.2 of the second housing element 52 and contains fluid 53.3b. The cooling channel 53.3a has a channel housing 53.3c, preferably as a plastic injection molded part. The channel housing 53.3c has a channel-like design at least over a section. The open side present here is arranged in a sealing manner on the outer surface 52.2 of the second housing element 52, so that the cooling channel 53.3a is closed on all sides for a fluid 53.3b to flow through. Between the edge area of the open side of the channel-like section and the outer surface 52.2, a sealing element 53.3d is arranged in a closed manner. The sealing element 53.3d can be injected, for example, in the plastic injection molded part of the duct housing. In the area of the resting sealing element 53.3d, a sealing surface 53.3e is formed in the outer surface 52.2. This can also be present as a groove-like indentation. Alternatively, the sealing element 53.3d can also be inserted into the groove-like depression. By means of the heat dissipation channel 53.3a is the heat dissipation of the heat dissipation area 54 compared to the versions of 1 and 2 significantly increased, in particular by a multiple. The heat can now also be dissipated via the fluid 53.3b. The heat dissipation channel 53.3a thus forms a new, third class of heat dissipation elements 54.3 for this first variant 31 and all possible other conceivable variants within the third performance class range 3. The fluid 53.3b is fed via an inlet connector 53.3f to the heat dissipation channel 53.3a and removed from there again through an outlet connector 53.3g. Both sockets 53.3f, 53.3g are preferably formed in one piece in the duct housing 53.3c.

The sealing surface 53.3e and a fastening structure (not shown) for the duct housing 53.3c represent an interface S for the arrangement or connection of the duct housing 53.3c to the outer surface 52.2.

The 3b shows a second variant 32 of control unit 100 with a performance class 100.x. Like variant 31 described above, variant 32 is also assigned to the third defined performance class range 3 of the 1234 control unit family, but with a higher performance class 100.x. The second variant 32 differs from the first variant 31 only in that the flow cross section Q formed in the channel housing 53.3c is larger than the flow cross section q in the first variant 31.

The 3c shows a modification of the first and / or second variant according to the 3a and 3b . The outer surface 52.2 has local indentations V, so that the course of the surface deviates from a single surface plane at these local points. In the area of a system contact A, the indentations V allow the gap distance a to be adjusted with regard to the TIM material 59 . Both the cooling structure 53.2 and the course of the channel housing 53.3c follow the outer surface 52.2 with the depressions V, so that the flow cross section q, Q is kept constant.

The 4 shows a variant 41 of the control device 100 with a performance class 100.4. Variant 41 is assigned to a fourth defined performance class range 4 of the 1234 control unit family. The fourth performance class range 4, for example, directly adjoins the aforementioned third performance class range 3 with corresponding variants of even higher performance classes 100.4. In addition to the flat outer surface 52.2 of the second housing element 52, the heat dissipation structure 53.2, and the heat dissipation channel 53.3, the heat dissipation area 54 is compared to the versions of FIG 1 , 2 , 3a and 3b extended with an additional cooling device based on the principle of evaporative cooling 53.4, for example way of a heat pipe or a vapor chamber. The cooling device 53.4 is injected, for example, within the plastic injection molded part of the duct housing 53.3c. Alternatively, the cooling device 53.4 is arranged on the outer surface 52.2 or inside the second housing element 52, for example in the area of the cooling structure 53.2. At least one side of the cooling device 53.4 is preferably in direct contact with the fluid 53.3b. By means of the cooling device according to the principle of evaporative cooling 53.4, the cooling capacity of the heat dissipation area 54 is compared to the versions of 1 , 2 , 3a , 3b significantly increased, in particular by a multiple. The heat can now also be dissipated via the cooling device 53.4. The cooling device 53.4 thus forms a new, fourth class of heat dissipation elements 54.4 for this variant 41 and all possible other conceivable variants within the fourth performance class range 4.

Very generally, for all variants 11, 21, 31, 32, 41, the second housing element 52 can be an injection molded part. As a result, the outer surface 52.2 of the second housing element 52 can then be configured as an essentially tool-side mold surface, with the mold surface being at least partially a one-piece mold of the heat dissipation elements 54.1, 54.2, 52.3, 54.4 of the respective class/class contained in the performance class range 1, 2, 3, 4 Classes of heat-emitting elements 54.1, 54.2, 52.3, 54.4 and/or a molding of at least one interface S for connecting partial elements 53.3c of the respective class/classes of heat-emitting elements 54.1, 54.2, 52.3, 54.4 contained in the performance class area 1, 2, 3, 4 .

The respective heat dissipation area 54 can then be specifically designed by adapting a jointly used injection molding tool. In this case, the injection molding tool has adaptable elements, for example as interchangeable inserts, in order to appropriately reproduce its molding geometry in the heat dissipation area 54 . A specific variant 11, 21, 31, 32, 41 of control unit 100 is thus formed in that the injection molding tool is used to mold the class/classes of heat dissipation elements 54.1, 54.2, 52.3, 54.4 and/or associated with the respective performance class range 1, 2, 3, 4. or adapted to mold an interface S for connecting partial elements 53.3c of the class/classes of heat dissipating elements 54.1, 54.2, 52.3, 54.4 assigned to the respective performance class range 1, 2, 3, 4.

In addition to the classes of heat dissipation elements 54.1, 54.2, 52.3, 54.4 shown as examples, additional classes of heat dissipation elements can be contained in other control device families. Furthermore, individual or all classes presented here may deviate from this. Overall, more or fewer classes of heat dissipation elements 54.1, 54.2, 52.3, 54.4 can be provided.

QUOTES INCLUDED IN DESCRIPTION

This list of documents cited by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA assumes no liability for any errors or omissions.

Patent Literature Cited

• DE 102015212721 A1 [0005]
• DE 102014106134 A1 [0006]
• DE 19911205 A1 [0007]

Claims (15)

Control unit family (1234) of a control unit platform with at least two, three, four or more variants (11, 21, 31, 32, 41) of control units (100) of different performance classes (100.1, 100.2, 100.3, 100.4, 100.x), the Variants (11, 21, 31, 32, 41) have at least one first and second housing element (51, 52) which, in the assembled state, form a cavity (55) in which an equipped circuit carrier (60) of a respective performance class ( 100.1, 100.2, 100.3, 100.4, 100.x), the circuit carrier (60) being at least partially connected with one of its two main sides (61, 62) at least indirectly with an inner surface (51.1, 52.1) of the second housing element (52) is at least indirectly in thermal contact (A) with the system, and a heat dissipation area (54) on an outer surface (52.2) of the second housing element (52) facing away from this one main side (62) of the circuit carrier (60). an environment adjoining the outer surface (52.2) is formed, characterized in that the control unit family (1234) comprises at least two, three or more different performance class areas (1, 2, 3, 4) with at least one in each performance class area (1, 2 , 3, 4) falling performance class (100.1, 100.2, 100.3, 100.4, 100.x) at least one variant (11, 21, 31, 32, 41) of the control unit (100), wherein variants (11, 21, 31, 32 , 41) of the control device (100) from two different performance class areas (1, 2, 3, 4) differ in their heat dissipation area (54) in that the cooling capacity of the respective heat dissipation area (54) corresponds to the performance class area (1, 2, 3, 4) is adjusted by the heat emission range (54) starting from a lowest specified power class range (1) up to a highest specified power class range (4) of the control unit family (1234) with increasingly higher power class range (1, 2, 3, 4) each by a additional new class of heat dissipation elements (54.1, 54.2, 52.3, 54.4) is expanded, which increases the cooling capacity of the heat dissipation area (54) of the respective performance class area (1, 2, 3, 4) compared to previous lower performance class areas (1, 2, 3, 4) elevated. Control unit family (1234) according to claim 1 , characterized in that the additional new class of heat dissipation elements (54.1, 54.2, 52.3, 54.4) of a performance class range (1, 2, 3, 4) is not included in all preceding lower performance class ranges (1, 2, 3, 4). Control unit family (1234) according to one of the Claims 1 or 2 , characterized in that the second housing element (52) is metallic, in particular made of aluminum or an aluminum alloy. Control unit family (1234) according to one of the preceding claims, characterized in that the second housing element (52) is an injection molded part and the outer surface (52.2) of the second housing element (52) is designed as an essentially tool-side mold surface, the mold surface at least partially having a One-piece molding of the heat dissipation elements (54.1, 54.2, 52.3, 54.4) of the respective class/classes of heat dissipation elements (54.1, 54.2, 52.3, 54.4) contained in the performance class area (1, 2, 3, 4) and/or a molding of at least one interface ( S) for connecting partial elements (53.3c) of the respective class/classes of heat dissipation elements (54.1, 54.2, 52.3, 54.4) contained in the performance class area (1, 2, 3, 4). Control unit family (1234) according to one of the preceding claims, characterized in that in a performance class area (1, 2, 3, 4), in particular a first performance class area (1) of the control unit family (1234), the heat emission area (54) exclusively or essentially by a flat outer surface (52.2) of the second housing element (52) is designed as a first class of heat dissipating elements (54.1). Control unit family (1234) according to claim 5 , characterized in that at least two variants of control units (100) of different performance classes within the first performance class range (1) differ in the surface area of the outer surface (52.2) of the second housing element (52), the surface area increasing as the performance class (100.1, 100.2, 100.3, 100.4, 100.x) is enlarged. Control unit family (1234) according to one of the preceding claims, characterized in that in a performance class area (2), in particular a second, larger performance class area (1, 2) of the control unit family (1234) immediately following the first, the heat emission area (54) by one of the outer surface (52.2) of the second housing element (52) protruding heat dissipation structure (53.2), in particular in the form of pin fins, is designed or expanded as a second class of heat dissipation elements (54.2). Control unit family (1234) according to claim 7 , characterized in that at least two Variants of control units (100) of different performance classes within the second performance class range (2) differ in the structural size of the respective heat dissipation structure (53.2), the structural size with increasing performance class (100.1, 100.2, 100.3, 100.4, 100.x) in relation to the number of their pinfins and/or the size of their pinfins is increased. Control unit family (1234) according to one of the preceding claims, characterized in that in a power class range (3), in particular a third power class range (1, 2, 3) of the control unit family (1234) immediately following the first and/or the second, which is larger, the Heat dissipation area (54) through a fluid (53.3b) directly containing the fluid (53.3b) that can flow through the outer surface (52.2) of the second housing element (52) is designed or expanded as a third class of heat dissipation elements (54.3). Control unit family (1234) according to claim 9 , characterized in that the heat dissipation duct (53.3a) is formed from a duct housing (53.3c) which is shaped like a channel over at least one section, in particular as a plastic injection molded part, the duct housing (53.3c) forming a seal in the region of its channel-like section from its open side the outer surface (52.2) of the second housing element (52) is arranged to form a cooling channel (53.3a) that is closed on all sides. Control unit family according to one of the claims 9 or 10 , characterized in that the heat dissipation duct (53.3a) has an inlet connection (53.3f) and an outlet connection (53.3g) for a cooling fluid (53.3b), both connections (53.3f, 53.3g) inside the duct housing (53.3c ) are in particular formed in one piece. Control unit family (1234) according to one of the claims 9 until 11 , characterized in that at least two variants of control units (100) of different performance classes within the third performance class range (3) differ in the flow cross section (q, Q) of the respective cooling duct (53.3c), the flow cross section (q, Q) increasing with the performance class (100.1, 100.2, 100.3, 100.4, 100.x) is enlarged. Control unit family (1234) according to one of the Claims 1 until 5 , 7 , and/or 9 to 11, characterized in that the two or more variants (11, 21, 31, 32, 41) of the control unit (100) belonging to the same performance class range (1, 2, 3, 4) have an identically designed heat dissipation area (54) and/or an identically designed second housing element (52). Method for forming a control device family (1234) of a control device platform according to one of Claims 1 until 13 , with the following method steps a) Specification of two, three or more different power class ranges (1, 2, 3, 4) for the control unit family (1234), each power class range (1, 2, 3, 4) having at least one control unit (100) is assigned to a performance class (100.1, 100.2, 100.3, 100.4, 100.x) falling within the performance class range (1, 2, 3, 4), b) defining classes of heat dissipation elements (54.1, 54.2, 52.3, 54.4), wherein starting from a lowest performance class range (1) up to a highest performance class range (4) for adapting the respective cooling range (54) of a control unit (100) within a performance class range (1, 2, 3, 4) to the performance class range (1, 2, 3 , 4) an additional new class of heat dissipation elements (54.1, 54.2, 52.3, 54.4) is assigned to each increasingly higher performance class range (1, 2, 3, 4), through which the cooling capacity of the heat dissipation area (54) of the respective performance class range (1, 2, 3, 4) compared to the preceding lower performance class ranges (1, 2, 3, 4), c) forming at least one variant (11, 21, 31, 32, 41) of the control unit (100) within the two, three or more defined performance class areas (1, 2, 3, 4), in that the respective heat dissipation area (54) is/are associated with the class/classes of heat dissipation elements (54.1, 54.2, 52.3 , 54.4) is formed or expanded. procedure after Claim 14 , characterized in that the respective heat dissipation area (54) is formed by an injection molding tool, at least in certain areas, the injection molding tool being designed to be adaptable in terms of its mold geometry in the area of the heat dissipation area (54), so that depending on the power class range (1, 2, 3, 4 ) in process step c) the injection molding tool for molding the class/classes of heat dissipation elements (54.1, 54.2, 52.3, 54.4) assigned to the respective performance class range (1, 2, 3, 4) and/or for molding an interface (S) for connecting Sub-elements (53.3c) of the respective performance class range (1, 2, 3, 4) associated class / classes of heat dissipation elements (54.1, 54.2, 52.3, 54.4) is adapted.

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