WO2013064343A1 - Driver assembly and method for manufacturing the same - Google Patents

Driver assembly and method for manufacturing the same Download PDF

Info

Publication number
WO2013064343A1
WO2013064343A1 PCT/EP2012/070021 EP2012070021W WO2013064343A1 WO 2013064343 A1 WO2013064343 A1 WO 2013064343A1 EP 2012070021 W EP2012070021 W EP 2012070021W WO 2013064343 A1 WO2013064343 A1 WO 2013064343A1
Authority
WO
WIPO (PCT)
Prior art keywords
driver
cavity
electronic module
driver assembly
housing
Prior art date
Application number
PCT/EP2012/070021
Other languages
French (fr)
Inventor
MingTao WANG
Guoan HE
Libo Wu
Original Assignee
Osram Gmbh
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Osram Gmbh filed Critical Osram Gmbh
Priority to US14/355,258 priority Critical patent/US9392716B2/en
Priority to DE112012004605.6T priority patent/DE112012004605B4/en
Publication of WO2013064343A1 publication Critical patent/WO2013064343A1/en

Links

Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/02—Arrangements of circuit components or wiring on supporting structure
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2039—Modifications to facilitate cooling, ventilating, or heating characterised by the heat transfer by conduction from the heat generating element to a dissipating body
    • H05K7/20436—Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing
    • H05K7/20445—Inner thermal coupling elements in heat dissipating housings, e.g. protrusions or depressions integrally formed in the housing the coupling element being an additional piece, e.g. thermal standoff
    • H05K7/20463—Filling compound, e.g. potted resin
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21K—NON-ELECTRIC LIGHT SOURCES USING LUMINESCENCE; LIGHT SOURCES USING ELECTROCHEMILUMINESCENCE; LIGHT SOURCES USING CHARGES OF COMBUSTIBLE MATERIAL; LIGHT SOURCES USING SEMICONDUCTOR DEVICES AS LIGHT-GENERATING ELEMENTS; LIGHT SOURCES NOT OTHERWISE PROVIDED FOR
    • F21K9/00—Light sources using semiconductor devices as light-generating elements, e.g. using light-emitting diodes [LED] or lasers
    • F21K9/20—Light sources comprising attachment means
    • F21K9/23—Retrofit light sources for lighting devices with a single fitting for each light source, e.g. for substitution of incandescent lamps with bayonet or threaded fittings
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K13/00—Apparatus or processes specially adapted for manufacturing or adjusting assemblages of electric components
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05K—PRINTED CIRCUITS; CASINGS OR CONSTRUCTIONAL DETAILS OF ELECTRIC APPARATUS; MANUFACTURE OF ASSEMBLAGES OF ELECTRICAL COMPONENTS
    • H05K7/00—Constructional details common to different types of electric apparatus
    • H05K7/20—Modifications to facilitate cooling, ventilating, or heating
    • H05K7/2039—Modifications to facilitate cooling, ventilating, or heating characterised by the heat transfer by conduction from the heat generating element to a dissipating body
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
    • F21V19/00—Fastening of light sources or lamp holders
    • F21V19/001—Fastening of light sources or lamp holders the light sources being semiconductors devices, e.g. LEDs
    • F21V19/003—Fastening of light source holders, e.g. of circuit boards or substrates holding light sources
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F21—LIGHTING
    • F21Y—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES F21K, F21L, F21S and F21V, RELATING TO THE FORM OR THE KIND OF THE LIGHT SOURCES OR OF THE COLOUR OF THE LIGHT EMITTED
    • F21Y2115/00—Light-generating elements of semiconductor light sources
    • F21Y2115/10—Light-emitting diodes [LED]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49117—Conductor or circuit manufacturing
    • Y10T29/49124—On flat or curved insulated base, e.g., printed circuit, etc.

Definitions

  • the present invention relates to a driver assembly and a method for manufacturing such driver assembly.
  • LED illuminating devices are widely used in daily life, and retrofit lamps taking LED, especially high-power LED, as a light source also have a great prospect.
  • Luminaries taking LED as a light source are also widely used, wherein it is a general configuration to put a driver inside, while in an illuminating device configured in such a manner, lots of heat generated by the driver in operation will increase the temperature of electronic assemblies on the driver, which will result in problems such as degraded performance, reduction of the service lifetime and even safety problem.
  • a potting material can be used, for instance, to be potted into inside of a whole driver housing, to allow the heat of the driver to be quickly transferred from the driver to the driver housing.
  • temperatures of most electronic assemblies on the driver do not ex- ceed the heat resistance standard, and only a small number of electronic assemblies that have a poor heat resistance property, that is, temperatures thereof exceed the heat resistance standard thereof, need to be subjected to thermal dis- sipation treatment for assuring normal operation of the illuminating device and thereby prolonging the service lifetime thereof.
  • thermal dis- sipation treatment for assuring normal operation of the illuminating device and thereby prolonging the service lifetime thereof.
  • Another possibility is to use a thermally conductive plastic to manufacture the driver housing, while the cost of this method is still too high, and the thermal dissipation effect that can be achieved is quite limited.
  • the electronic devices that need to be subjected to thermal dissipation treatment also can be selectively coated with a thermal dissipation layer or selectively potted. Though this method has the advantage of a low cost, it is hard to control an operation process of selective coating or potting and final consistence as the thermal dissipation treatment is locally needed; moreover, as the electronic devices having a poor thermal resistance cannot directly contact the driver housing, the thermal properties of the retrofit lamp inside the driver are also limited to some degree.
  • the object of the present invention lies in providing a novel driver assembly.
  • the driver assembly of the present invention is easily manufactured, has a low cost, and realizes favorable thermal dissipation of electronic modules inside.
  • a driver assembly comprising a driver housing and a driver, wherein the driver comprises at least a first portion and a second portion, the first portion having a lower heat resistance than the second portion, wherein the driver housing comprises at least a first cavity for at least partially accommodating the first portion and a second cavity for accommodating the second portion, and a potting material is potted into the first cavity to envelop the first portion.
  • the concept of the present invention lies in locally enveloping a portion of the driver that has a lower heat resistance than the other portions in the driver housing accommodating the driver, that is, the portion that has a low heat resis- tance is subjected to a thermal dissipation treatment merely via a potting material potted into the first cavity corresponding to the portion that has a low heat resistance.
  • the portion such as specific electronic module that has a low heat resistance is thermally connected with the driver housing via a small amount of potting material, and the driver, especially the portion that has a low heat resistance therein is subjected to a thermal dissipation treatment .
  • the first portion is a first electronic module
  • the second portion comprises a PCB board for mounting the first electronic module and a second electronic module mounted on the PCB board.
  • Part of region of the driver has a higher heat resistance than the first portion, or relatively is not sensitive to temperature, therefore, thermal dissipation requirements of the second electronic module can be satisfied by thermal dissipation properties of the driver housing per se .
  • the driver housing comprises a bottom for supporting the PCB board, the first cavity is defined by inner closed ribs formed in one piece with the bottom, and the second cavity is a space in the driver housing with exception of the first cavity. That is to say, apart from defining the first cavity in the driver housing, remaining space of the driver housing is defined as the second cavity.
  • the first cavity has a geometrical shape matched with the first elec- tronic module. Accordingly, the first electronic module can be enveloped with as little potting material as possible to save costs.
  • the first cavity merely accommodates the first electronic module.
  • the first electronic module such as that having a big height can be directly inserted into the first cavity and enveloped by the potting material .
  • Such first electronic module having a big height is inductor, for example.
  • the first portion further comprises a heat conductor connected to an end surface of the first electronic module facing the first cavity, and the heat conductor and the first electronic module as a whole are at least partially jointly accommodated in the first cavity.
  • the first electronic module such as that having a small height should be inserted into the first cavity having the potting material with the help of the heat conductor, and the potting material at least completely envelopes the heat conductor, and ideally, also envelopes at least part of the first electronic module.
  • Such first electronic module having a small height is a chip, for example .
  • the heat conductor is fixed on the end surface via bonding, clipping or welding. This can realize a fixed mechanical connection and thermal connection between the heat conductor and the first electronic module.
  • the heat conductor is a heat conduction stick or a heat conduc- tion flake.
  • the heat conductor stick can be bonded or welded on the end surface of the first electronic module; and the heat conduction flake can be engaged with, via a clip, and bonded or welded on the end surface of the first electronic module.
  • the object of thermal conduction also can be achieved with other heat conductors having a suitable structure or similar shape.
  • the first electronic module is an IC chip or an inductor, or other electronic elements, wherein the IC chip has a smaller height than electronic devices likes the inductor.
  • the potting material is a solidifiable liquid or gel .
  • the present invention further relates to a method for manufacturing the driver assembly, including steps of :
  • Fig. 1 is an exploded three dimensions-view of a driver assembly of the present invention
  • Fig. 2 is a top three dimensions-view of a driver housing in Fig. 1;
  • Fig. 3 is a lateral sectional view of a first variant of the driver assembly of the present invention
  • Fig. 4 is an example of a second variant of the driver assembly of the present invention
  • Fig. 5 is another example of the second variant of the driver assembly of the present invention.
  • Fig. 6 is a flow chart of a method for manufacturing the driver assembly of the present invention.
  • Fig. 1 is an exploded three dimensions-view of a driver assembly of the present invention.
  • the driver assembly comprises a driver 3 and a driver housing 1 accommodating the driver 3.
  • the driver 3 comprises a PCB board 5 and a plurality of second electronic modules 8 mounted at both sides thereof, wherein a first electronic module 2.1 that has a lower heat resistance than the second electronic modules 8 acts as a first portion 2 located on a side surface of the PCB board 5 facing the driver housing 1, and the PCB board 5 and at least one second electronic module 8 act as a second portion 2' of the driver 3 having a high heat resistance.
  • an inner cavity of the driver housing 1 at least partially matches the driver 3 in shape.
  • Fig. 2 is a top three dimensions-view of a driver housing 1 of the driving assembly of the present invention. It can be seen clearly from Fig. 2 that a first cavity 4 is formed in the driver housing 1, and it is defined by inner closed ribs extending towards the driver 3 on a bottom B of the driver housing 1 by a process such as injection molding or similar technology. Apart from the first cavity 4, remaining space in the driver housing 1 is defined to be a second cavity 4' for accommodating the second portion 2' .
  • the first cavity 4 should have a shape matched with that of the first electronic module 2.1 to be enveloped, and is slightly bigger than the first electronic module 2.
  • Fig. 3 is a lateral sectional view of an embodiment of the driver assembly of the present invention.
  • the first electronic module 2.1 such as inductor as the first portion 2 of the driver 3 has a big height, in which case, the first electronic module 2.1 per se can be totally inserted into the first cavity 4 formed in the driver housing 1.
  • a liquid or gelatinous potting material 6 in the first cavity 4 is extruded by the first electronic module 2.1 inserted into the first cavity 4 to fill the whole first cavity 4.
  • the first electronic module 2.1 is enveloped after the potting material 6 is cooled, which is reflected ideally in Fig. 3 that the first electronic module 2.1 is totally enveloped in the first cavity 4. Therefore, heat from the first elec- tronic module 2.1 can be transferred via the potting material 6 to the driver housing 1 for thermal dissipation.
  • Fig. 4 and Fig. 5 show two examples of another variant of the driver assembly of the present invention.
  • the first electronic module 2.1 such as IC chip
  • the first portion 2 of the driver 3 has a small height, in which case, the first portion 2 therefore can additionally comprise a heat conductor 2.2.
  • the heat conductor 2.2 is inserted into the first cavity 4, and only the heat conductor 2.2 per se or the heat conductor 2.2 and the first electronic module 2.1 are jointly enveloped.
  • the heat conductor 2.2 for example, also can be a heat conduction stick 2.21 shown in Fig. 4 or a heat conduction flake 2.22 shown in Fig. 5.
  • the heat conductor 2.2 also can be configured to be a heat conduction member in other forms mounted on an end surface F of the first electronic module 2.1.
  • the heat conduction stick 2.21 can be directly, for example, welded or bonded on the end surface F of the first electronic module 2.1.
  • the heat conduction flake 2.22 has a clip portion configured to be mounted on the end surface F of the first electronic module 2.1, and the heat conduction flake 2.22 can be engaged with the end surface F of the first electronic module 2.1 via the clip and is further fixed via welding or bonding. It should be noted that such connection manners also can realize a thermal connec- tion.
  • the heat conductor 2.2 is completely inserted into the first cavity 4 and is enveloped by the potting material 6.
  • at least part of the first electronic module 2.1 is also enveloped by the potting material 6.
  • heat from the first electronic module 2.1 is guided by the heat conductor 2.2 to the driver housing 1.
  • Fig. 6 is a flow chart of a method for manufacturing a driver assembly of the present invention.
  • a manufacturing process is as follows: step 1, providing a driver 3 having a first por- tion 2 and a second portion 2' ; step 2, providing a driver housing 1, wherein inner closed ribs extending towards the driver 3 on a bottom B of the driver housing 1 define a first cavity 4 for accommodating the first portion 2 of the driver 3, and remaining space of the driver housing 1 is defined as a second cavity 4' for accommodating the second portion 2' of the driver 3, wherein the first portion 2 has a lower heat resistance than the second portion 2'; and , step 3, potting a small amount of potting material 6 into the first cavity 4, thereafter, arranging the driver 3 in the driver housing 1 such that the first portion 2 just can be completely or partially inserted into the first cavity 4 to form an enveloped structure .

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  • Engineering & Computer Science (AREA)
  • Microelectronics & Electronic Packaging (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Optics & Photonics (AREA)
  • General Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Cooling Or The Like Of Electrical Apparatus (AREA)
  • Cooling Or The Like Of Semiconductors Or Solid State Devices (AREA)

Abstract

The present invention relates to a driver assembly, comprising a driver housing (1) and a driver (3), the driver (3) comprising at least one first portion (2) and a second portion (2'), the first portion (2) having a lower heat resistance than the second portion (2'), wherein the driver housing (1) comprises at least one first cavity (4) for at least partially accommodating the first portion (2) and a second cavity (4') for accommodating the second portion (2'), and a potting material (6) is potted into the first cavity (4) to envelop the first portion (2). In addition, the present invention further relates to a method for manufacturing such driver assembly. The driver assembly of the present invention is easily manufactured, has a low cost, and realizes favorable thermal dissipation of electronic modules inside.

Description

Description
Driver Assembly and Method for Manufacturing the Same
Technical Field
The present invention relates to a driver assembly and a method for manufacturing such driver assembly.
Background Art At present, LED illuminating devices are widely used in daily life, and retrofit lamps taking LED, especially high-power LED, as a light source also have a great prospect. Luminaries taking LED as a light source are also widely used, wherein it is a general configuration to put a driver inside, while in an illuminating device configured in such a manner, lots of heat generated by the driver in operation will increase the temperature of electronic assemblies on the driver, which will result in problems such as degraded performance, reduction of the service lifetime and even safety problem. In the prior art, a potting material can be used, for instance, to be potted into inside of a whole driver housing, to allow the heat of the driver to be quickly transferred from the driver to the driver housing. Generally, temperatures of most electronic assemblies on the driver do not ex- ceed the heat resistance standard, and only a small number of electronic assemblies that have a poor heat resistance property, that is, temperatures thereof exceed the heat resistance standard thereof, need to be subjected to thermal dis- sipation treatment for assuring normal operation of the illuminating device and thereby prolonging the service lifetime thereof. In this situation, if the driver is wholly potted with a traditional method, unnecessary waste will be in- curred, and thereby the manufacturing cost will be increased. Another possibility is to use a thermally conductive plastic to manufacture the driver housing, while the cost of this method is still too high, and the thermal dissipation effect that can be achieved is quite limited. The electronic devices that need to be subjected to thermal dissipation treatment also can be selectively coated with a thermal dissipation layer or selectively potted. Though this method has the advantage of a low cost, it is hard to control an operation process of selective coating or potting and final consistence as the thermal dissipation treatment is locally needed; moreover, as the electronic devices having a poor thermal resistance cannot directly contact the driver housing, the thermal properties of the retrofit lamp inside the driver are also limited to some degree. Summary of the Invention
Therefore, the object of the present invention lies in providing a novel driver assembly. The driver assembly of the present invention is easily manufactured, has a low cost, and realizes favorable thermal dissipation of electronic modules inside.
A driver assembly is provided according to the present invention, comprising a driver housing and a driver, wherein the driver comprises at least a first portion and a second portion, the first portion having a lower heat resistance than the second portion, wherein the driver housing comprises at least a first cavity for at least partially accommodating the first portion and a second cavity for accommodating the second portion, and a potting material is potted into the first cavity to envelop the first portion.
The concept of the present invention lies in locally enveloping a portion of the driver that has a lower heat resistance than the other portions in the driver housing accommodating the driver, that is, the portion that has a low heat resis- tance is subjected to a thermal dissipation treatment merely via a potting material potted into the first cavity corresponding to the portion that has a low heat resistance. As a result, the portion such as specific electronic module that has a low heat resistance is thermally connected with the driver housing via a small amount of potting material, and the driver, especially the portion that has a low heat resistance therein is subjected to a thermal dissipation treatment .
According to a preferred solution of the present invention, the first portion is a first electronic module, and the second portion comprises a PCB board for mounting the first electronic module and a second electronic module mounted on the PCB board. Part of region of the driver has a higher heat resistance than the first portion, or relatively is not sensitive to temperature, therefore, thermal dissipation requirements of the second electronic module can be satisfied by thermal dissipation properties of the driver housing per se .
In a preferred solution of the present invention, the driver housing comprises a bottom for supporting the PCB board, the first cavity is defined by inner closed ribs formed in one piece with the bottom, and the second cavity is a space in the driver housing with exception of the first cavity. That is to say, apart from defining the first cavity in the driver housing, remaining space of the driver housing is defined as the second cavity.
In a preferred solution of the present invention, the first cavity has a geometrical shape matched with the first elec- tronic module. Accordingly, the first electronic module can be enveloped with as little potting material as possible to save costs.
In a preferred solution of the present invention, the first cavity merely accommodates the first electronic module. In this case, the first electronic module such as that having a big height can be directly inserted into the first cavity and enveloped by the potting material . Such first electronic module having a big height is inductor, for example.
In a preferred solution of the present invention, the first portion further comprises a heat conductor connected to an end surface of the first electronic module facing the first cavity, and the heat conductor and the first electronic module as a whole are at least partially jointly accommodated in the first cavity. In this case, the first electronic module such as that having a small height should be inserted into the first cavity having the potting material with the help of the heat conductor, and the potting material at least completely envelopes the heat conductor, and ideally, also envelopes at least part of the first electronic module. Such first electronic module having a small height is a chip, for example .
In a preferred solution of the present invention, the heat conductor is fixed on the end surface via bonding, clipping or welding. This can realize a fixed mechanical connection and thermal connection between the heat conductor and the first electronic module.
In another preferred solution of the present invention, the heat conductor is a heat conduction stick or a heat conduc- tion flake. The heat conductor stick can be bonded or welded on the end surface of the first electronic module; and the heat conduction flake can be engaged with, via a clip, and bonded or welded on the end surface of the first electronic module. Of course, the object of thermal conduction also can be achieved with other heat conductors having a suitable structure or similar shape.
In another preferred solution of the present invention, the first electronic module is an IC chip or an inductor, or other electronic elements, wherein the IC chip has a smaller height than electronic devices likes the inductor.
Preferably, the potting material is a solidifiable liquid or gel .
In addition, the present invention further relates to a method for manufacturing the driver assembly, including steps of :
(a) providing a driver having at least one first portion and a second portion; (b) providing a driver housing, wherein the driver housing is formed with a first cavity for accommodating at least one first portion of the driver and a second cavity for accommodating the second portion of the driver, wherein the first portion has a lower heat resistance than the second portion;
(c) filling a potting material in the first cavity; and
(d) mounting the driver in the driver housing, wherein the first portion is at least partially inserted into the first cavity corresponding thereto to encapsulate the first portion .
It shall be understood that both the above general description and the following detailed description are for illustrative and explanative purposes in order to provide further de- scription of the claimed present invention.
Brief Description of the Drawings
The accompanying drawings constitute a part of the present Description and are used to provide further understanding of the present invention. Such accompanying drawings illustrate the embodiments of the present invention and are used to describe the principles of the present invention together with the Description. In the accompanying drawings the same components are represented by the same reference numbers. As shown in the drawings : Fig. 1 is an exploded three dimensions-view of a driver assembly of the present invention; Fig. 2 is a top three dimensions-view of a driver housing in Fig. 1;
Fig. 3 is a lateral sectional view of a first variant of the driver assembly of the present invention; Fig. 4 is an example of a second variant of the driver assembly of the present invention;
Fig. 5 is another example of the second variant of the driver assembly of the present invention; and
Fig. 6 is a flow chart of a method for manufacturing the driver assembly of the present invention.
Detailed Description of the Embodiments
Fig. 1 is an exploded three dimensions-view of a driver assembly of the present invention. The driver assembly comprises a driver 3 and a driver housing 1 accommodating the driver 3. The driver 3 comprises a PCB board 5 and a plurality of second electronic modules 8 mounted at both sides thereof, wherein a first electronic module 2.1 that has a lower heat resistance than the second electronic modules 8 acts as a first portion 2 located on a side surface of the PCB board 5 facing the driver housing 1, and the PCB board 5 and at least one second electronic module 8 act as a second portion 2' of the driver 3 having a high heat resistance. In order to assure the driver 3 to be fixedly accommodated in the driver housing 1, an inner cavity of the driver housing 1 at least partially matches the driver 3 in shape.
Fig. 2 is a top three dimensions-view of a driver housing 1 of the driving assembly of the present invention. It can be seen clearly from Fig. 2 that a first cavity 4 is formed in the driver housing 1, and it is defined by inner closed ribs extending towards the driver 3 on a bottom B of the driver housing 1 by a process such as injection molding or similar technology. Apart from the first cavity 4, remaining space in the driver housing 1 is defined to be a second cavity 4' for accommodating the second portion 2' . The first cavity 4 should have a shape matched with that of the first electronic module 2.1 to be enveloped, and is slightly bigger than the first electronic module 2.
Fig. 3 is a lateral sectional view of an embodiment of the driver assembly of the present invention. The first electronic module 2.1 such as inductor as the first portion 2 of the driver 3 has a big height, in which case, the first electronic module 2.1 per se can be totally inserted into the first cavity 4 formed in the driver housing 1. At this time, a liquid or gelatinous potting material 6 in the first cavity 4 is extruded by the first electronic module 2.1 inserted into the first cavity 4 to fill the whole first cavity 4. The first electronic module 2.1 is enveloped after the potting material 6 is cooled, which is reflected ideally in Fig. 3 that the first electronic module 2.1 is totally enveloped in the first cavity 4. Therefore, heat from the first elec- tronic module 2.1 can be transferred via the potting material 6 to the driver housing 1 for thermal dissipation.
Fig. 4 and Fig. 5 show two examples of another variant of the driver assembly of the present invention. Different from the embodiment shown in Fig. 3, the first electronic module 2.1, such as IC chip, comprised by the first portion 2 of the driver 3 has a small height, in which case, the first portion 2 therefore can additionally comprise a heat conductor 2.2. The heat conductor 2.2 is inserted into the first cavity 4, and only the heat conductor 2.2 per se or the heat conductor 2.2 and the first electronic module 2.1 are jointly enveloped. The heat conductor 2.2, for example, also can be a heat conduction stick 2.21 shown in Fig. 4 or a heat conduction flake 2.22 shown in Fig. 5. Of course, the heat conductor 2.2 also can be configured to be a heat conduction member in other forms mounted on an end surface F of the first electronic module 2.1. The heat conduction stick 2.21 can be directly, for example, welded or bonded on the end surface F of the first electronic module 2.1. The heat conduction flake 2.22 has a clip portion configured to be mounted on the end surface F of the first electronic module 2.1, and the heat conduction flake 2.22 can be engaged with the end surface F of the first electronic module 2.1 via the clip and is further fixed via welding or bonding. It should be noted that such connection manners also can realize a thermal connec- tion. During the enveloping process, the heat conductor 2.2 is completely inserted into the first cavity 4 and is enveloped by the potting material 6. In an ideal situation, at least part of the first electronic module 2.1 is also enveloped by the potting material 6. As a result, heat from the first electronic module 2.1 is guided by the heat conductor 2.2 to the driver housing 1.
Fig. 6 is a flow chart of a method for manufacturing a driver assembly of the present invention. A manufacturing process is as follows: step 1, providing a driver 3 having a first por- tion 2 and a second portion 2' ; step 2, providing a driver housing 1, wherein inner closed ribs extending towards the driver 3 on a bottom B of the driver housing 1 define a first cavity 4 for accommodating the first portion 2 of the driver 3, and remaining space of the driver housing 1 is defined as a second cavity 4' for accommodating the second portion 2' of the driver 3, wherein the first portion 2 has a lower heat resistance than the second portion 2'; and , step 3, potting a small amount of potting material 6 into the first cavity 4, thereafter, arranging the driver 3 in the driver housing 1 such that the first portion 2 just can be completely or partially inserted into the first cavity 4 to form an enveloped structure .
The above is merely preferred embodiments of the present invention but not to limit the present invention. For the person skilled in the art, the present invention may have various alterations and changes. Any alterations, equivalent substitutions, improvements, within the spirit and principle of the present invention, should be covered in the protection scope of the present invention.
List of reference signs
1 driver housing
2 first portion having a low heat resistance 2' second portion having a high heat resistance 2.1 first electronic module
2.2 heat conductor
2.21 heat conduction stick
2.22 heat conduction flake
3 driver
4 first cavity
4' second cavity
5 PCB board
6 potting material
8 second electronic module
B bottom
F end surface of first electronic module

Claims

Patent claims
1. A driver assembly, comprising a driver housing (1) and a driver (3), the driver (3) comprising at least one first portion (2) and a second portion (2'), the first portion (2) having a lower heat resistance than the second portion (2'), wherein the driver housing (1) comprises at least one first cavity (4) for at least partially accommodating the first portion (2) and a second cavity (4') for accommodating the second portion (2'), and a potting material (6) is potted into the first cavity (4) to envelop the first portion (2) .
2. The driver assembly according to Claim 1, wherein the first portion (2) is a first electronic module (2.1), and the second portion (2') comprises a PCB board (5) for mounting the first electronic module (2.1) and at least one second electronic module (8) mounted on the PCB board (5) .
3. The driver assembly according to Claim 2, wherein the driver housing (1) comprises a bottom (B) for supporting the PCB board (5), the first cavity (4) is defined by inner frame formed in one piece with the bottom (B) , and the second cavity (4') is the space in the driver housing (1) other than the first cavity (4) .
4. The driver assembly according to Claim 3, wherein the first cavity (4) has a geometrical shape matched with the first electronic module (2.1) .
5. The driver assembly according to any one of Claims 1-4, wherein the first cavity (4) merely accommodates the first electronic module (2.1) .
6. The driver assembly according to any one of Claims 1-4, wherein the first portion (2) further comprises a heat conductor (2.2) connected to an end surface (F) of the first electronic module (2.1) facing the first cavity (4), and the heat conductor (2.2) and the first electronic module (2.1) as a whole are at least partially accommodated in the first cavity (4) .
7. The driver assembly according to Claim 6, wherein the heat conductor (2.2) is fixed on the end surface (F) via bonding, clipping or welding.
8. The driver assembly according to Claim 7, wherein the heat conductor (2.2) is heat conduction stick (2.21) or a heat conduction flake (2.22) .
9. The driver assembly according to any one of Claims 1-4, wherein the first electronic module (2.1) is an IC chip or an inductor .
10. The driver assembly according to any one of Claims 1-4, wherein the potting material (6) is a solidifiable liquid or gel .
11. A method for manufacturing a driver assembly, including steps of :
(a) providing a driver (3) having at least one first portion (2) and a second portion (2');
(b) providing a driver housing (1) , wherein the driver housing (1) is formed with a first cavity (4) for accommodating the at least one first portion (2) of the driver (3) and a second cavity (4') for accommodating the second portion (2') of the driver (3), wherein the first portion (2) has a lower heat resistance than the second portion (2');
(c) filling a potting material (6) in the first cavity (4) ; and
(d) mounting the driver (3) in the driver housing (1) , wherein the first portion (2) is at least partially inserted into the first cavity (4) corresponding thereto to encapsulate the first portion (2) .
PCT/EP2012/070021 2011-11-03 2012-10-10 Driver assembly and method for manufacturing the same WO2013064343A1 (en)

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DE112012004605.6T DE112012004605B4 (en) 2011-11-03 2012-10-10 Driver assembly and method of making same

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CN201110344449.6 2011-11-03
CN201110344449.6A CN103090338B (en) 2011-11-03 2011-11-03 Actuator assembly and its manufacturing method

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US9392716B2 (en) 2016-07-12
DE112012004605T5 (en) 2014-08-14
US20140247563A1 (en) 2014-09-04
CN103090338B (en) 2018-10-09
CN103090338A (en) 2013-05-08

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