Electronic Circuit Unit with Insulating Compound for Inductance Reduction

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Solution Overview

Problem

Existing electronic circuit units for inverters and converters in hybrid and electric vehicles require additional contact elements for electrical connections, leading to increased complexity, size, and cost, as well as higher inductance and heat generation due to the need for creepage current distances and air-gap distances.

Innovation Solution

The electronic circuit unit features terminal contacts and pads encapsulated in an electrically insulating compound, eliminating the need for additional contact elements, with conductor bars and insulating elements arranged to reduce inductance and allow for a compact, simple design, and the use of a potting compound for comprehensive insulation and protection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional contact elements are used for electrical connections between terminal contacts and terminal pads, then reliable electrical contact is achieved, but device complexity and number of components increase

Engineering Contradiction:

Improveelectrical contact reliabilityVSAvoidnumber of contact elements

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the functions of electrical insulation and mechanical protection into a single insulating compound that encapsulates the entire contact region. This eliminates the need for separate insulating elements and additional contact elements, reducing component count while maintaining reliable electrical contact between terminal contacts and terminal pads.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating compound acts as an intermediary substance that fills the space between electrical components. It provides electrical insulation while allowing thermal conduction, and protects the contact region without requiring additional mechanical fastening elements or insulating structures.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If creepage current distances and air-gap distances are maintained for electrical insulation, then electrical safety is ensured, but inductance increases and heat generation increases

Engineering Contradiction:

Improveelectrical insulation safetyVSAvoidheat generation

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The patent changes the physical state and properties of the insulating compound to optimize its performance. By selecting a compound with high thermal conductivity and appropriate dielectric strength, it achieves electrical insulation without requiring large creepage distances, thereby reducing inductance and heat generation while maintaining electrical safety.

Inventive Principle:

Principle #35Parameter changes

3Reliability

If additional contact elements and insulation structures are added, then electrical insulation is improved, but manufacturing cost and production complexity increase

Engineering Contradiction:

Improveelectrical insulationVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent segments the manufacturing process into two main stages: assembly of electrical components on the carrier substrate, and subsequent encapsulation with insulating compound. This segmentation allows for standardized production of electrical assemblies that can then be uniformly insulated, simplifying manufacturing and reducing costs compared to assembling individual insulated components.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insulating compound serves multiple functions simultaneously: electrical insulation, mechanical protection, thermal management, and structural support. This multi-functionality eliminates the need for separate components for each function, reducing manufacturing complexity and cost while improving overall system reliability.

Inventive Principle:

Principle #25Self-service

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 design reduces inductance and heat generation, allows for a more compact and cost-effective construction, and provides enhanced protection against mechanical and environmental factors by eliminating the need for additional contact elements and minimizing creepage current distances.

Implementation Method 1

the at least one terminal contact and the at least one terminal pad are surrounded in the region of the electrical point of contact by an electrically insulating compound

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Implementation Method 2

the carrier substrate being arranged on an upper side of a heat sink

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10130015B2Electronic circuit unit

Publication Date: 2018.11.13 ROBERT BOSCH GMBH

AI summary

An electronic circuit unit (1) comprising at least one electrical or electronic device (8) with at least one terminal contact (101), the at least one terminal contact (101) being connected in an electrically conducting manner to at least one terminal pad (100), at least one terminal contact (101) and at least one terminal pad (100) are surrounded in the region of the electrical point of contact by an electrically insulating compound (9), the electrical or electronic device (8) being arranged outside the electrically insulating compound (9).