Adjustable Power Semiconductor Module Terminals
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Solution Overview
Problem
Existing power semiconductor modules are inflexible in adjusting the length of external terminals protruding from the case, making it difficult to adapt to changes in intended use without requiring multiple types of terminals and complex installation processes.
Innovation Solution
The power semiconductor module design incorporates terminals with first and second protrusions that can be locked into through-holes of a printed circuit board, allowing for adjustable terminal lengths by switching between these protrusions without replacing the terminals, enabling flexible length adjustments without the need for different terminal types or complex installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If external terminals have fixed lengths protruding from the case, then the module structure is simple and easy to manufacture, but the module cannot adapt to changes in intended use requiring different terminal lengths
Solution Approach 1:
The terminal structure incorporates movable protrusions that can be repositioned along the terminal body. The first protrusion and second protrusion can switch positions to change the effective length of the terminal protruding from the case, transforming a static fixed-length terminal into a dynamic adjustable-length terminal that adapts to different usage requirements
Solution Approach 2:
A single terminal design with multiple protrusions serves multiple functions: it can provide different protruding lengths (first length with first protrusion, second length with second protrusion) depending on the intended use. This multi-functional terminal replaces the need for multiple different terminal types, achieving versatility while maintaining structural simplicity
2Adaptability or versatility
If multiple types of terminals with different lengths are used to meet different usage requirements, then adaptability is improved, but the number of parts and installation complexity increase
Solution Approach 1:
Multiple terminal functions (different lengths) are merged into a single terminal body. The first protrusion and second protrusion are integrated into one terminal structure, allowing the terminal to provide different effective lengths by switching which protrusion is engaged with the through-hole, thereby reducing the quantity of different terminal types needed
Solution Approach 2:
The terminal is designed as a universal component that can fulfill multiple length requirements through its reconfigurable protrusions. This single universal terminal replaces what would otherwise require multiple specialized terminals of different lengths, reducing part inventory and assembly complexity
3Reliability
If press-fit parts are added to external terminals for securing during soldering, then bonding reliability is improved, but the terminal structure becomes more complex
Solution Approach 1:
The locking function and the length-adjustment function are merged into the same protrusion structure. The first protrusion and second protrusion serve dual purposes: they provide mechanical locking when engaged with the through-hole during soldering (improving reliability) and enable length adjustment by switching which protrusion is engaged (providing adaptability), thereby avoiding separate locking mechanisms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design allows for flexible adjustment of terminal lengths by changing the locking mechanism within the existing terminals, reducing the need for multiple terminal types and simplifying the installation process, thereby enhancing adaptability and efficiency.
Implementation Method 1
a heat treatment at 200° C. up to about 350° C. is performed. At that time, before the solder is heated and cooled for solidification
Implementation Method 2
before the solder is heated and cooled for solidification
Implementation Method 3
the external terminals have press-fit parts for press-fitting into the through-holes
Data Source
AI summary
A power semiconductor module includes an insulating circuit substrate; a printed circuit board disposed over the insulating circuit substrate; and a plurality of terminals each having a rod-shaped portion and including a first protrusion and a second protrusion each protruding laterally form a side face of the rod-shaped portion; wherein at least one of the plurality of terminals is inserted to one of the through-holes of the printed circuit board and is locked to the one of the through-holes via the first protrusion, and wherein at least another one of the plurality of terminals is inserted to another one of the through-holes of the printed circuit board and is locked to said another one of the through-holes via the second protrusion, and an end of the at least another one of the plurality of terminals is electrically connected to a conductive plate on the insulating circuit substrate.