Busbar Locating Component for Perpendicular Transistor Positioning
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Solution Overview
Problem
Designing compact, power-dense electronic devices with proper thermal control and manufacturability challenges, particularly in power inverters that convert high-voltage DC to AC, where space is limited and mass production requires efficient assembly and automation.
Innovation Solution
A busbar locating component with bays and slots configured to position transistors and busbars perpendicular to the busbar layer, featuring releasable detents, terminal pass-throughs, and attachments for circuit boards, enabling precise positioning and connection while allowing for predictable tolerances and efficient thermal management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If transistors and busbars are positioned perpendicular to the busbar layer in a compact arrangement, then power density and thermal management are improved, but manufacturing precision and assembly complexity increase
Solution Approach 1:
The busbar locating component is designed with pre-formed slots and bays that define precise positions for busbars and transistor assemblies before assembly. The slots are configured with specific dimensions and orientations to receive busbars in a perpendicular arrangement, establishing positioning constraints in advance to achieve high power density while maintaining manufacturing precision through pre-planned geometry rather than post-assembly adjustment
Solution Approach 2:
The invention changes the spatial parameter arrangement by positioning busbars and transistor assemblies perpendicular to the busbar layer rather than in traditional parallel configurations. This parameter change enables improved power density and thermal management while the slot dimensions and bay geometries are specifically designed to accommodate this perpendicular arrangement with appropriate tolerances
2Volume of moving object
If a compact busbar locating component with integrated slots and bays is used, then device compactness is improved, but assembly complexity increases
Solution Approach 1:
The busbar locating component merges multiple functions into a single integrated structure: it provides slots for busbar positioning, bays for transistor assembly containment, attachment features for securing the busbar layer, and structural support for maintaining perpendicular orientation. This consolidation reduces the number of separate components needed, achieving compactness while managing assembly complexity through functional integration
Solution Approach 2:
The busbar locating component serves multiple purposes simultaneously: it acts as a positioning fixture for busbars, a mounting structure for transistor assemblies, a support element for the busbar layer, and a thermal management conduit. This multi-functionality reduces the overall component count and device volume while the modular slot and bay design maintains reasonable assembly complexity
3Temperature
If perpendicular positioning of transistors and busbars is implemented, then thermal management efficiency is improved, but assembly time increases
Solution Approach 1:
The perpendicular positioning geometry is pre-established through the slot and bay configurations in the busbar locating component. The slots are designed with specific angles and dimensions that guide busbars into perpendicular orientation, and the bays are shaped to receive transistor assemblies in the correct orientation. This preliminary geometric preparation enables efficient thermal management through optimized heat dissipation paths while reducing assembly time by eliminating the need for complex alignment procedures during assembly
Data Source
AI summary
A busbar locating component includes: one or more first attachments configured for attaching a busbar layer to the busbar locating component; one or more bays each configured to contain and position an assembly of transistors essentially perpendicular to the busbar layer for connection; and a plurality of slots, each slot configured to contain and position a busbar relative to the busbar layer for connection.