Annular Bus Bar Segmentation for Power Conversion Inductance Reduction
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Solution Overview
Problem
Power conversion apparatuses face challenges in reducing inductance, particularly in bus bars, which restricts switching speed and current handling capacity due to restricted electric current paths around connection terminals.
Innovation Solution
The power conversion apparatus incorporates a pair of bus bars with body plate parts facing each other in the thickness direction and annularly formed terminal connection parts, increasing electric current paths and reducing inductance by providing multiple paths for current flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If conventional bus bar structures with limited current paths are used, then manufacturing is simpler, but inductance is high which restricts switching speed and current handling capacity
Solution Approach 1:
The bus bar is segmented into multiple terminal connection parts (first, second, third, fourth terminal connection parts) arranged around the semiconductor module, creating multiple parallel current paths instead of a single path. This segmentation allows current to flow through multiple routes simultaneously, reducing overall inductance and enabling faster switching speeds.
Solution Approach 2:
The terminal connection parts are arranged in a multi-dimensional configuration around the semiconductor module, transitioning from a linear or planar current path to a three-dimensional radial arrangement. This spatial distribution in multiple dimensions creates shorter and more numerous current loops, significantly reducing inductance while maintaining structural integrity.
2Power
If bus bars with multiple terminal connection parts are implemented, then current handling capacity increases, but manufacturing complexity increases
Solution Approach 1:
Multiple terminal connection parts are merged into a single integrated bus bar structure rather than being separate components. This combining approach maintains the current handling capacity benefits of multiple connection points while simplifying manufacturing by treating the multi-terminal bus bar as one piece, reducing assembly steps and potential connection points of failure.
Solution Approach 2:
The bus bar structure serves multiple functions simultaneously: it provides electrical connection, structural support, and heat dissipation pathways. The same terminal connection parts that handle current also serve as mounting points for the semiconductor module, eliminating the need for separate fastening hardware and simplifying the overall manufacturing process.
3Temperature
If traditional bus bar designs are used, then assembly is simpler, but heat dissipation is insufficient
Solution Approach 1:
The bus bar structure incorporates locally optimized features at each terminal connection part, with connection surfaces and cross-sectional areas specifically designed for heat dissipation at those locations. Each terminal connection part has enhanced thermal contact area with the semiconductor module, creating localized heat sinks that efficiently conduct heat away from high-current regions without requiring a complete redesign of the entire structure.
Data Source
AI summary
A power conversion apparatus includes: a semiconductor module including a built-in switching element; and a pair of bus bars connected to a power terminal of the semiconductor module. The pair of bus bars has body plate parts that are arranged so as to at least partially face each other in a thickness direction, and pluralities of terminal connection parts that are branched from the body plate parts and to which the power terminal is connected. At least one of the pair of bus bars has a plurality of annular parts that are annularly formed so as to include the plurality of terminal connection parts.