Advanced Institute's new filtering solution for copper busbar of electric vehicles/plug-in hybrid vehicles - customized ferrite core

Obviously, two completely different deformation reactions occurred under pressure. Compared with TIM in standard supplier testing, although they belong to the same material, TIM in simulated products is more prone to deformation. Specifically, at a target deformation of 40%, the pressure generated on each component is approximately 75 kPa, far below the stress capacity of each component. The reason for doing this is that in the physical model, the amount of material that needs to be moved is much less (about half) than the supplier's standard testing equipment. In addition, TIM materials can easily enter the open space around them and deform without resistance. In this case, TIM may also deform into the open space between components, resulting in significant differences in shape between the two curves.

After understanding that TIM is more prone to deformation in applications than previously thought, engineers can now easily design a less flexible thermal pad. This type of thermal pad may have a lower price or higher thermal conductivity; Alternatively, he can also choose to increase the strain rate to improve production efficiency while maintaining pressure requirements. Of course, he can also design according to the selected thermal pad and application conditions, setting a wide range of safety factors for the stress limit of the components.

In summary, it has been proven that the TIM properties in applications differ significantly from those provided by suppliers. Supplier data is only applicable for selecting the most flexible gasket and cannot predict the actual properties. Under the same testing conditions, it is necessary to compare multiple suppliers. It has been proven that there are generally two methods to reduce stress during deformation when selecting gaskets. The first method is to utilize the viscoelasticity of the gasket, allowing for stress relaxation as much as possible while deformation occurs. This is achieved by slowing down the deformation speed of TIM and performing step-by-step or staged deformation. In addition, creep can be utilized to apply slight pressure over a longer period of time, causing the material to descend to its final position. The second method can achieve unobstructed deformation; Please remember that TIM does not compress. To achieve this, our goal should be to minimize the amount of material movement as much as possible. The method to achieve this goal is to use extremely thin TIM to fully cover the gap tolerance, and the X and Y dimensions of the material should be as small as possible to ensure that the components are fully covered only after deformation. In addition, the pressure release area should be divided according to the geometric shape of the gasket, so that the material can flow into this area during the deformation process - if necessary, multiple gaskets can even be used, and the surface smoothness should be improved as much as possible. All the above variables should be considered separately. Of course, after a reasonable combination of these variables, the pressure during the deformation process will be significantly reduced. This can not only protect fragile components, improve production efficiency, but also enhance the heat conduction effect in applications.