Busbar Terminal Overlap for Compact Power Conversion
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Solution Overview
Problem
The existing electric power conversion apparatuses face challenges in minimizing size due to the alternating arrangement of positive and negative busbar terminals, which necessitates large intervals between them, thereby increasing the size of the apparatus in the stacking direction of semiconductor modules.
Innovation Solution
The apparatus incorporates a configuration where the positive and negative busbars have their terminals overlapping partially in the busbar base extending direction, with an insulator in between, allowing for reduced intervals between the terminals while ensuring electrical insulation, thereby minimizing the overall size and lowering inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If positive and negative busbar terminals are arranged alternately in a row in the stacking direction of semiconductor modules, then electrical insulation between positive and negative terminals is ensured, but the interval between terminals increases and the size of the apparatus in the stacking direction cannot be minimized
Solution Approach 1:
The busbar terminals are arranged in the width direction (horizontal dimension) rather than alternating in the stacking direction (vertical dimension). The positive and negative busbar terminals are positioned side-by-side in the width direction with their bases extending in the stacking direction, allowing insulation in the horizontal plane instead of requiring vertical separation.
Solution Approach 2:
An insulator is introduced as an intermediary component between the positive and negative busbar terminals. The insulator is positioned between the terminals in the width direction and extends in the stacking direction, providing electrical insulation while allowing the terminals to be closely spaced horizontally without requiring large vertical intervals.
2Reliability
If sufficient intervals are secured between alternately arranged positive and negative busbar terminals, then electrical insulation is maintained, but the overall size of the electric power conversion apparatus increases
Solution Approach 1:
The arrangement shifts from vertical alternation (stacking direction) to horizontal positioning (width direction). This dimensional change allows the apparatus volume to be reduced in the stacking direction while maintaining insulation through horizontal separation and the use of insulators.
Solution Approach 2:
The insulator dimensions and material properties are optimized to provide sufficient electrical insulation with minimal space occupation. By changing the insulator parameters (size, shape, material), the apparatus can maintain reliable insulation while minimizing overall volume.
3Volume of stationary object
If busbar terminals are placed closer together, then the size of the apparatus is reduced, but inductance increases due to reduced spacing
Solution Approach 1:
The terminals are positioned close together in the width direction rather than being separated in the stacking direction. This spatial arrangement reduces the apparatus size while the insulator configuration and terminal orientation minimize the harmful inductive effects by optimizing the current path geometry.
Solution Approach 2:
The busbar terminal dimensions, shapes, and orientations are optimized to reduce inductance. By changing geometric parameters of the terminals and their arrangement, the apparatus achieves compact size while controlling the inductive effects through optimized current flow paths.
Data Source
AI summary
An electric power conversion apparatus includes at least one semiconductor module, a capacitor, a pair of positive and negative busbars and an insulator. The positive busbar includes a positive busbar base protruding from the capacitor in a Y direction and at least one positive busbar terminal extending perpendicular to an X direction. The negative busbar includes a negative busbar base protruding from the capacitor in the Y direction and at least one negative busbar terminal extending perpendicular to the X direction. The positive and negative busbar bases are arranged to have their major surfaces facing each other in a Z direction. The positive and negative busbar terminals at least partially overlap each other in the X direction with the insulator interposed therebetween. The at least one semiconductor module has a pair of positive and negative power terminals connected respectively to the positive and negative busbar terminals.