Bent Leadframe Terminal Layout for Uniform Semiconductor Current Sharing
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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
Engineering 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
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
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
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
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
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
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
Data Source
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.


