Bent Leadframe Terminal Layout for Uniform Semiconductor Current Sharing

Resolve Bottlenecks,
Find Innovative Solutions
Generate Solutions

Solution Overview

Problem

Conventional power converter designs for electric axle drives in motor vehicles face issues with non-uniform current distribution and differential loading of semiconductors due to the positioning of semiconductor components, which affects the efficiency and reliability of the power conversion process.

Innovation Solution

A method for manufacturing a terminal apparatus that involves bending a pre-machined sheet metal element to create a leadframe with a central power-source connection, allowing for a uniform distribution of currents between semiconductor components, and connecting control terminals to a corresponding terminal pin, thereby achieving consistent loading and improved current conduction.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a conventional leadframe design is used with distributed terminal positioning, then the manufacturing process is simplified, but the current distribution becomes non-uniform and semiconductor loading becomes differential

Engineering Contradiction:
Improvecurrent distribution uniformityVSAvoidleadframe structure complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent applies asymmetry by positioning the power-source connection centrally rather than distributing terminals symmetrically. The leadframe structure features a central power terminal with semiconductor components arranged around it, creating an asymmetric layout that ensures uniform current distribution from the central source to all semiconductors, eliminating the non-uniform current distribution problem of conventional symmetric designs

Inventive Principle:
Principle #4Asymmetry

Solution Approach 2:

The patent transitions from a planar two-dimensional terminal arrangement to a three-dimensional structure by bending the sheet metal element. The edge region is bent to bring the first electric terminal device and path section into closer proximity, creating a folded configuration that achieves uniform current distribution while managing the complexity through spatial optimization rather than increasing planar dimensions

Inventive Principle:
Principle #17Another dimension (Dimensionality change)

2Volume of moving object

If the leadframe is shortened to bring connecting elements closer, then the module size is reduced, but the manufacturing precision required increases

Engineering Contradiction:
Improvemodule sizeVSAvoidterminal positioning precision
Core Design Contradiction:
Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-machining the sheet metal element with precisely positioned terminals and path sections before the bending operation. The first electric terminal device, control terminal, and path section are pre-positioned with accurate spacing and alignment, ensuring that when the edge region is bent to shorten the leadframe, the terminal positioning precision is already established and maintained

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The patent segments the leadframe manufacturing into distinct operations: pre-machining the sheet metal element with specific terminal positions and path sections, then separately bending the edge region to achieve the shortened configuration. This segmentation allows each operation to be optimized independently, maintaining manufacturing precision while achieving compact module size

Inventive Principle:
Principle #1Segmentation

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 approach enables a uniform current distribution and consistent loading of semiconductors, enhancing the efficiency and reliability of power conversion in electric axle drives by allowing closer proximity of connecting elements at different potentials within the module.

Implementation Method 1

In the bending step, an edge region of the sheet metal is bent such that the first electric terminal device and the path section are brought together

Methodology Applied
Scientific EffectPlastic deformation: Deformation

Data Source

PatentUS20240021436A1Method and apparatus for manufacturing a terminal apparatus for connecting at least one electrical or electronic component for an electrical or electronic module
Publication Date: 2024.01.18 ZF FRIEDRICHSHAFEN AG
  • US20240021436A1 patent drawing
  • US20240021436A1 patent drawing
  • US20240021436A1 patent drawing

AI summary

A method for manufacturing a terminal apparatus for connecting a component for an electrical module includes bending a pre-machined sheet metal element, having a first electric terminal device for connecting to a first potential, a control terminal having a control contact, and a second electric terminal device arranged between the first electric terminal device and the control terminal and separated from the first electric terminal device by a gap, and for connecting to a second electrical potential, further having a path section including a first path for contact-connection with a terminal for the second electrical potential of the component, and a second path arranged in parallel with the first, and wherein an edge region of the sheet metal is bent such that the first electric terminal device and the path section are brought together such that the first electric terminal device and the path section overlap.