Stretchable Converter Housing with Faraday Cage for Semiconductor Explosion Containment
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Solution Overview
Problem
Power semiconductors in converters can 'explode' due to uncontrollable power loss, leading to short circuits, extreme heating, and collateral damage, causing converter failure and loss of function in applications like aircraft electric drives.
Innovation Solution
A housing for the converter's output stage is designed with a flexible, non-conductive shell made of stretchable material, supported by a metal lattice Faraday cage, filled with insulating oil, which absorbs and distributes the energy from an exploding semiconductor by expanding into a spherical shape, minimizing damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a rigid housing is used to contain the output stage, then structural strength is improved, but the housing will rupture during semiconductor explosion
Solution Approach 1:
The patent applies the dynamics principle by making the housing shell stretchable rather than rigid. The shell is designed to dynamically expand during a semiconductor explosion event, allowing it to accommodate the plasma expansion without rupturing. This dynamic adaptation resolves the contradiction between needing structural strength and maintaining integrity during explosive events.
Solution Approach 2:
The patent applies parameter changes by altering the physical state and properties of the housing material. The stretchable material changes its volume and shape parameters during an explosion, transitioning from a compact state to an expanded state that can contain the plasma. This parameter change allows the housing to maintain integrity while accommodating the explosive energy.
2Loss of energy
If a stretchable material is used for the housing shell, then explosion energy absorption is improved, but electrical insulation is worsened
Solution Approach 1:
The patent applies composite materials by combining stretchable material with insulating oil and a metal lattice Faraday cage. The stretchable shell provides explosion energy absorption, the insulating oil maintains electrical insulation properties, and the Faraday cage provides additional electrical protection. This composite structure resolves the contradiction between energy absorption and electrical insulation.
Solution Approach 2:
The patent uses insulating oil as an intermediary substance between the stretchable shell and the semiconductor components. The oil fills the housing and provides electrical insulation, allowing the stretchable shell to expand during explosion while maintaining the necessary electrical isolation between components.
3Object-affected harmful factors
If the housing volume is increased to contain plasma expansion, then damage containment is improved, but device size is worsened
Solution Approach 1:
The patent applies dynamics by designing a housing that dynamically changes its volume based on operational conditions. During normal operation, the housing maintains a compact size. During an explosion, the stretchable shell expands to increase volume and contain the plasma. This dynamic volume adjustment resolves the contradiction between damage containment and device size.
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
The solution effectively contains and weakens the explosion, preventing housing rupture and maintaining functionality by absorbing and distributing the explosion energy, thus protecting the converter and associated systems.
Implementation Method 1
The housing is completely filled with an insulating oil or another insulating medium
Implementation Method 2
a metal lattice, which also performs the function of an earthing Faraday cage
Implementation Method 3
The hood being stretchable so as to enlarge the volume enclosed by the hood in the event of an explosion of a power semiconductor as a result of the explosion energy
Data Source
AI summary
A housing is provided for an output stage with power semiconductors of a modular converter. The housing includes a stretchable hood arranged on the base plate. The housing further includes a metallic lattice formed in or on the hood and forming a Faraday cage, wherein the hood is configured to be stretchable so as to enlarge the volume enclosed by the hood in the event of an explosion of a power semiconductor as a result of the explosion energy, without destroying the hood. An output stage, a converter, and an aircraft are also provided.