Power Converter Coolant Sensor Insulation for Compact Thermal Control
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Solution Overview
Problem
Existing power converters face challenges in accurately controlling the temperature of semiconductor modules due to the increased size caused by the need for insulation between electronic components and temperature sensors, especially when the temperature sensor is positioned inside the converter.
Innovation Solution
The power converter design incorporates a temperature sensor with a conductive member, including a thermistor, surrounded by a resin wall formed of an insulating material, allowing it to be positioned closer to the semiconductor module without increasing the converter's size by eliminating the need for a predetermined inter-part distance for insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the temperature sensor is positioned inside the power converter to improve temperature control accuracy, then the temperature measurement precision is improved, but the device size increases due to the required insulation distance
Solution Approach 1:
An insulating member (resin wall) is introduced as an intermediary between the temperature sensor and electronic components. This mediator provides the necessary electrical insulation while occupying minimal space, allowing the sensor to be positioned close to the semiconductor module without requiring large clearance distances that would increase the overall converter volume.
Solution Approach 2:
The insulating member is implemented as a thin resin wall that surrounds the temperature sensor. This thin film structure provides adequate electrical insulation between the sensor and electronic components while minimizing the space required, enabling compact positioning of the sensor inside the power converter housing.
2Measurement precision
If the temperature sensor is positioned close to the semiconductor module to improve temperature control, then the temperature control accuracy is improved, but the insulation requirement between electronic components and sensor increases device complexity
Solution Approach 1:
The insulating member is integrated with the temperature sensor assembly as a unified structure. The resin wall is formed as part of the sensor housing or mounting structure, combining the insulation function with the sensor support function, thereby reducing overall device complexity while maintaining close positioning of the sensor to the semiconductor module.
Solution Approach 2:
The insulating member is made of resin material that provides both electrical insulation and mechanical support functions. This composite approach uses a single material to fulfill multiple requirements (insulation, structural support, and close spacing), simplifying the overall design compared to using separate insulation components and sensor mountings.
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 configuration enhances the accuracy of temperature control and reduces the power converter's size by ensuring insulation between electronic components and the temperature sensor, improving the internal layout and manufacturing efficiency.
Implementation Method 1
at least a part of the conductive member is surrounded by a resin wall formed of an insulating material
Implementation Method 2
a temperature sensor provided on the base member, to sense the temperature of the coolant circulating through the coolant flow path
Implementation Method 3
the temperature sensor has a conductive member including at least a thermistor
Data Source
AI summary
A power converter comprising: a power conversion circuit to convert an input power into a direct current power or an alternating current power; a base member made of resin on which the power conversion circuit is mounted; a cover member, wherein the power conversion circuit is housed between the cover member and the base member; a coolant flow path provided in an interior of the base member, through which a coolant for cooling the power conversion circuit is circulated; and a temperature sensor provided on the base member, to sense the temperature of the coolant circulating through the coolant flow path, wherein the temperature sensor has a conductive member including at least a thermistor, and at least a part of the conductive member is surrounded by a resin wall formed of an insulating material.