Power Converter Discharge Resistor Cooling via Wiring Pattern
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Solution Overview
Problem
The reliability of power converters is compromised due to inadequate cooling of discharge resistors that generate heat during the discharge of electric charges accumulated in smoothing capacitors.
Innovation Solution
A power converter design that includes a discharge resistor connected in parallel to a smoothing capacitor, where the discharge resistor's heat is directed towards a cooler via a wiring pattern, and the resistor is configured to overlap the cooler, enhancing cooling efficiency and reducing the risk of open failures, while maintaining a compact size for the connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the discharge resistor is used to discharge electric charges from the smoothing capacitor, then the capacitor can be discharged effectively, but the discharge resistor generates heat that impairs reliability
Solution Approach 1:
The patent converts the harmful heat generated by the discharge resistor into a beneficial cooling effect by directing it toward the cooler. The wiring pattern is designed to conduct heat from the discharge resistor to the cooler, transforming the harmful thermal energy into a useful cooling mechanism for the semiconductor modules.
Solution Approach 2:
The wiring pattern serves as an intermediary thermal conduction path between the discharge resistor and the cooler. It acts as a heat transfer medium that carries thermal energy from the discharge resistor to the cooler, enabling indirect cooling of the resistor through the circuit board structure.
2Temperature
If the discharge resistor is placed away from the cooler, then the circuit board layout is simpler, but the cooling effect is insufficient
Solution Approach 1:
The patent merges the discharge resistor with the cooling system by positioning it adjacent to the cooler and designing the wiring pattern to create a thermal conduction path. This integration allows the discharge resistor to utilize the cooler's cooling capacity while maintaining a compact and relatively simple circuit board layout.
3Reliability
If the discharge resistor is cooled effectively, then reliability is improved, but the connector size increases
Solution Approach 1:
The patent applies local quality by providing cooling specifically to the discharge resistor through the wiring pattern and cooler arrangement, rather than cooling the entire circuit board. This localized cooling approach improves reliability of the discharge resistor while maintaining a compact connector size by not requiring extensive cooling infrastructure.
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
Effective cooling of the discharge resistor improves the reliability and heat radiation performance of the power converter, preventing impairment and maintaining a compact connector size.
Implementation Method 1
a cooler that cools the semiconductor modules
Implementation Method 2
a cooler that cools the semiconductor modules
Implementation Method 3
the discharge resistor generates heat with the discharging of the electric charges
Implementation Method 4
a greater part of the heat generated by the discharge resistor can be directed toward the control terminal via the wiring pattern
Data Source
AI summary
A power converter includes a body including a switching element; a plurality of semiconductor modules each having a control terminal projected from the body; a circuit board controlling the switching element; a cooler that cools the semiconductor modules; a smoothing capacitor smoothing direct-current voltage applied to the switching element; a discharge resistor disposed on a surface of the circuit board and electrically connected parallel to the smoothing capacitor. The semiconductor modules are mounted on the circuit board with the control terminal, the discharge resistor includes a first connecting portion at one end of the discharge resistor in a longitudinal direction thereof and a second connecting portion at an other end of the discharge resistor in the longitudinal direction, and the first connecting portion is connected to the control terminal via a wiring pattern provided on the surface of the circuit board.