Power Conversion Bus Bar Vibration Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
There is a need to minimize the number of components in power conversion devices for hybrid and electric vehicles while maintaining resistance against vibrations caused by road and engine/motor variations.
Innovation Solution
A power conversion device design that includes a power semiconductor module, a plate conductor, and a resin sealing material with a supporting member, where the plate conductor is buried within the resin sealing material facing the electric components, enhancing vibration resistance while reducing component count.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the number of components is reduced for miniaturization, then the device size is minimized, but the resistance against vibration deteriorates
Solution Approach 1:
The patent merges the supporting member and electric component into a single integrated structure. The electric component is directly mounted on the supporting member that is formed as an integral part of the housing, eliminating the need for separate mounting brackets or fasteners. This integration reduces the total component count while maintaining structural integrity and vibration resistance through the unified design.
Solution Approach 2:
The supporting member serves multiple functions simultaneously: it provides structural support for the electric component, acts as a mounting surface, and functions as part of the housing structure. This multi-functionality allows the removal of dedicated mounting components while maintaining both support and vibration resistance functions, thereby reducing component count without sacrificing reliability.
2Device complexity
If components are integrated to reduce component count, then manufacturing complexity is reduced, but assembly precision requirements increase
Solution Approach 1:
The supporting member is pre-formed with integrated mounting features and positioning structures during the housing manufacturing process. The electric component mounting surfaces and alignment features are prepared in advance as part of the housing fabrication, allowing for precise positioning without requiring complex assembly operations. This preliminary preparation of mounting structures reduces the precision demands on final assembly while maintaining integration benefits.
Data Source
AI summary
To suppress reduction in resistance against vibrations, while reducing the number of components, a power conversion device including a power semiconductor module that converts a DC current into an AC current, a plate conductor that transfers the DC current or the AC current, a resin sealing material that seals the plate conductor, and an electric component that is used to control the power semiconductor module has the resin sealing material include a supporting member. The supporting member supports the electric component, and the plate conductor is buried in a portion of the resin sealing material that is disposed to face the electric component.