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DE-102025101983-B3 - Insulation mat for the power electronics of a motor vehicle

DE102025101983B3DE 102025101983 B3DE102025101983 B3DE 102025101983B3DE-102025101983-B3

Abstract

The invention relates to an insulation mat for the power electronics of a motor vehicle, comprising at least the following components: - an electrically and thermally insulating carrier film, and - Electrically insulating and thermally conductive filling material. The insulating mat is characterized primarily by the fact that the carrier film has at least one guide recess by means of which the carrier film can be aligned during installation. An insulation mat with guide recesses in the carrier film is proposed, which simplifies assembly.

Inventors

  • Jens Krüger

Assignees

  • DR. ING. H.C. F. PORSCHE AKTIENGESELLSCHAFT

Dates

Publication Date
20260513
Application Date
20250121

Claims (9)

  1. Insulation mat (1) for power electronics (2) of a motor vehicle, comprising at least the following components: - an electrically and thermally insulating carrier film (3); and - electrically insulating and thermally conductive filler material (4), wherein the carrier film (3) has at least one guide recess (5) by means of which the carrier film (3) can be aligned during assembly, characterized in that at least one guide recess (5) is formed with at least one additional degree of freedom to a guide direction to a complementary guide means (6).
  2. Insulation mat (1) according to Claim 1 , wherein the insulation mat (1) has a plurality of guide recesses (5).
  3. Insulation mat (1) according to one of the preceding claims, wherein at least two of the guide recesses (5) are designed or arranged differently such that at least one of the two guide recesses (5) cannot be applied to the complementary guide means (6) for the respective other guide recess (5).
  4. Insulation mat (1) according to one of the preceding claims, wherein the carrier film (3) comprises mounting tabs (7).
  5. Insulation mat (1) according to one of the preceding claims, wherein the insulation mat (1) is designed as a mountable prefabricated component.
  6. Pre-assembly unit (8) for power electronics (2) of a motor vehicle, comprising at least the following components: - a current-carrying component (9); and - an insulating mat (1) attached to the current-carrying component (9) according to a Claim 1 until Claim 5 , wherein complementary guiding means (6) of the current-carrying component (9) are accommodated in the guiding recesses (5) of the insulation mat (1).
  7. Power electronics (2) for a motor vehicle, comprising at least the following components: - an insulating mat (1) after a Claim 1 until Claim 5 ; - a current-carrying component (9); and - a heat sink (10); wherein the filling material (4) of the insulation mat (1) is arranged between the current-carrying component (9) and the heat sink (10), and wherein complementary guiding means (6) of the current-carrying component (9), its assembly, the heat sink (10) and/or a housing are received in the guiding recesses (5) of the insulation mat (1).
  8. Power electronics (2) according to Claim 7 , wherein the current-carrying component (9) is a component of a Battery Junction Box (11).
  9. Manufacturing process for power electronics (2) according to Claim 7 or Claim 8 , comprising the following steps: a. Providing the insulation mat (1); b. Sliding the guide recesses (5) onto complementary guide means (6) of the current-carrying component (9), the heat sink (10) or a housing, c. Attaching the insulation mat (1) to the current-carrying component (9) or the heat sink (10), and d. Pressing the respective other of the current-carrying component (9) and heat sink (10) against the side of the insulation mat (1) opposite the attachment from step c.

Description

The invention relates to an insulating mat for power electronics of a motor vehicle, a pre-assembly unit with such an insulating mat for power electronics of a motor vehicle, power electronics with such a pre-assembly unit for a motor vehicle, and a manufacturing method for power electronics. Power electronics for battery-electric or hybrid vehicles are known from industrial practice, enabling the control of the vehicle's high-voltage electrical system. Such power electronics include, for example, a battery junction box and a current control unit. The battery junction box contains components such as fuses, contactors, and busbars or conductors to the individual components of the high-voltage system. The current control unit includes components such as power converters, for example, AC-DC converters or DC-DC converters. The electrical power losses of both the battery junction box components and the power control unit components must be dissipated by means of cooling. Solutions are known from industrial practice where a common cooling plate, which is integrated into the power control unit, is used for both the power control unit and the battery junction box. The high-voltage components of the battery junction box that require cooling are thermally coupled to the cooling plate by means of a thermally conductive filler material, also known as a gap pad or gap filler. The filler material is, for example, bonded to the cooling plate using a carrier film. The disadvantage is that the filling material is difficult to install. DE 102 37 716 A1 Disclosing an electronic unit with a thermally conductive distribution element, in which a thermally conductive film is arranged between an electronic assembly and a housing and is pressed in a defined manner in the area of a through-opening via a connecting element with a clamping ring and axial stop, thereby achieving a reproducible contact pressure and a reliable thermal contact without over-compression of the film; the film can be multi-layered and/or segmented and have cutouts for feedthroughs. DE 20 2024 102 566 U1 The disclosure includes a Gappad, a Gappad device, and an electronic system, wherein the Gappad comprises an elastic, compressible core element and a conductive, preferably graphitic, sheathing that covers the core element on at least two side surfaces as well as on the top and bottom surfaces, so that heat dissipation from the top to the bottom surface is possible; at least one tab projecting laterally beyond an end face is provided for fixing to a heat sink and is held clamped in the Gappad device between a frame element and the heat sink, wherein an internal self-adhesive layer is optionally provided for positioning on the frame element, and several Gappads can be arranged side by side and clamped together. DE 10 2023 200 062 A1 Disclosing a busbar arrangement for cooling a busbar, comprising a layered structure of busbar, first thermal conductivity material, insulating film, second thermal conductivity material, and cooling medium, wherein the insulating film protrudes on both sides in the second horizontal direction relative to the thermal conductivity materials, and the protrusion is bonded to a housing to prevent creepage paths; the connection between the insulating film and the housing can be made by ultrasonic welding, laser welding, injection molding (film insert molding), or bonding; the housing can be made of plastic (optionally fiber-reinforced); and the cooling medium can be made of metal, in particular aluminum or copper, and provide efficient heat dissipation. Based on this, the present invention aims to overcome, at least partially, the disadvantages known from the prior art. The features of the invention are defined in the independent claims, for which advantageous embodiments are shown in the dependent claims. The features of the claims can be combined in any technically meaningful way, whereby the explanations in the following description and features from the figures, which comprise supplementary embodiments of the invention, can also be used. The invention relates to an insulation mat for the power electronics of a motor vehicle, comprising at least the following components: - an electrically and thermally insulating carrier film; and - Electrically insulating and thermally conductive filling material. The insulation mat is characterized primarily by the fact that the backing film at least It has a guide recess by means of which the carrier film can be aligned during installation. Unless explicitly stated otherwise, ordinal numbers used in the preceding and following descriptions serve solely for unambiguous differentiation and do not indicate any order or ranking of the components referred to. An ordinal number greater than one does not necessarily imply the presence of another such component. An insulating mat for the power electronics of a motor vehicle, preferably an electric or hybrid vehicle, is proposed here. The power electronics