3D Conducting Structure Positioning for Low-Inductance Power Substrates
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Solution Overview
Problem
Modern power substrates with raised insulating structures face challenges in achieving low inductance designs that are tolerant to production variations and require precise positioning of connecting elements for external electrical contacting, while maintaining a defined creepage distance and minimizing inductance in commutation circuits.
Innovation Solution
The electrical arrangement features a power substrate with an insulating structure and a three-dimensional conducting structure that includes positioning lugs and recesses for precise alignment, allowing for external electrical contacting without increasing creepage distance, and is produced through laser-cutting and bending of sheet metal, ensuring accurate positioning and reduced tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a connecting element is positioned to project beyond the packaging edge for external electrical contacting, then external electrical contacting is enabled, but the creepage current distance between upper and lower sides is reduced
Solution Approach 1:
The connecting element is designed with a three-dimensional configuration where the connection region extends in a direction parallel to the power substrate surface rather than vertically projecting beyond the packaging edge. This dimensional change allows external electrical contacting while maintaining the creepage distance requirement by keeping the connection region at a defined distance from the insulating structure.
2Adaptability or versatility
If the connecting element is bent at an angle to connect contact region and connection region, then three-dimensional electrical connection is achieved, but positioning precision and tolerance control deteriorate
Solution Approach 1:
The connecting element is segmented into distinct functional regions: a contact region with a flat contact surface for precise positioning on the power substrate, a connecting region for external electrical contacting, and a connecting portion that connects these regions. The contact region includes positioning features such as lugs or tabs that engage with corresponding features on the insulating structure, enabling precise positioning while allowing the connecting portion to provide the necessary three-dimensional connection path.
Solution Approach 2:
The insulating structure serves as an intermediary element that provides a recess or window to receive the contact region of the connecting element. This intermediary structure enables precise positioning of the contact region while maintaining the required distance between the connection region and the insulating structure, thus controlling tolerances and ensuring manufacturing precision.
3Loss of energy
If the connecting element extends close to the insulating structure to reduce inductance, then inductance is minimized, but the risk of contacting the insulating structure increases
Solution Approach 1:
The connecting element is designed with different spatial configurations for different functional regions. The contact region is positioned close to the insulating structure to minimize inductance, while the connection region is maintained at a defined distance from the insulating structure to prevent contact. The connecting portion transitions between these two positions, optimizing electrical performance while ensuring reliable operation.
4Ease of manufacture
If conventional production methods are used for the conducting structure, then manufacturing simplicity is maintained, but positioning accuracy and interlocking fit are insufficient
Solution Approach 1:
The connecting element is designed with pre-formed positioning features such as lugs, tabs, or cutouts that are created during the manufacturing process. These positioning features are preliminarily configured to engage with corresponding features on the insulating structure, ensuring accurate positioning and interlocking fit before the assembly step. This preliminary configuration of positioning features maintains manufacturing simplicity while achieving high positioning accuracy.
Data Source
AI summary
A production method and an electrical arrangement (1) are proposed. The electrical arrangement (1) comprises a power substrate (2) with an electrical conductive track (3), an insulating structure (4) and a sheet metal conducting structure (5) having a first contact region (6), a connection region (11) and a first connecting region (9) between the first contact region (6) and the connection region (11), wherein the contact region (6) is connected to the electrical conductor track (3) electrically, in particular with a material bond, in a recess (12) in the insulating structure (4), merges into the connecting region (9) at an angle along an edge (7) running in an X direction and has a lug (8) for positioning the conducting structure (5), which lug extends in a Y direction over an imaginary extension of the edge (7).