Equal-Length Current Paths in Vehicle Electronic Modules
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Solution Overview
Problem
Existing electronic modules for electric vehicles face challenges such as high production costs, limited availability of frame modules using novel semiconductors, and increased leakage inductance due to asymmetrical power switch arrangements, which complicate cooling and scalability.
Innovation Solution
An electronic module design featuring a semiconductor bridge circuit with high-side and low-side switches connected in parallel, with equal length and antiparallel current paths to reduce leakage inductance, allowing for symmetrical arrangement and improved cooling, and enabling scalable and efficient power delivery to electric machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If frame modules with established semiconductor materials are used, then production costs are reduced and manufacturing is simplified, but availability is limited for novel wide bandgap semiconductors like SiC and GaN
Solution Approach 1:
The patent divides the power switch assembly into discrete, modular components that can be independently packaged and connected. This segmentation allows the use of novel wide bandgap semiconductors while maintaining manufacturing simplicity through standardized connection processes.
Solution Approach 2:
The patent creates a universal connection concept that can accommodate both established semiconductor materials and novel wide bandgap semiconductors. The standardized connection structure provides multi-functionality, allowing the same manufacturing approach to work with different semiconductor types.
2Device complexity
If high-side and low-side power switches are arranged successively from the intermediate circuit capacitor, then the construction is simplified, but leakage inductance increases resulting in poor switching behavior
Solution Approach 1:
The patent intentionally introduces asymmetry in the arrangement of power switches relative to the intermediate circuit capacitor. By positioning the high-side and low-side switches at different locations rather than symmetrically, the patent reduces the commutation cell area and minimizes leakage inductance, thereby improving switching behavior.
Solution Approach 2:
The patent transitions from a one-dimensional successive arrangement to a two-dimensional spatial distribution of power switches. By utilizing different spatial dimensions and positions around the intermediate circuit capacitor, the patent optimizes current paths to reduce leakage inductance while maintaining construction simplicity.
3Ease of operation
If a multidimensional bus bar concept is used to conduct current from battery terminal to intermediate circuit capacitor, then current conduction is achieved, but bus bar cross section requirements increase and cooling becomes difficult
Solution Approach 1:
The patent merges the current conduction function with the cooling function by integrating thermal management pathways into the existing current paths. This combination eliminates the need for separate, oversized bus bars, reducing cross-section requirements while improving cooling efficiency through direct thermal contact points.
Data Source
AI summary
The invention relates to an electronic module for an electric drive in a vehicle, comprising an input-side electrical connection for inputting an input current generated by an energy source; an intermediate circuit with a capacitor; a semiconductor bridge circuit, connected in parallel to the intermediate circuit, wherein the bridge circuit comprises a high-side switch, and a low-side switch connected in series to the high-side switch, wherein the high-side switch is connected to the input-side electrical connection via a first current path, wherein the low-side switch is connected to the input-side electrical connection via a second current path, wherein the first current path and the second current path are the same length; and an output-side electrical connection for outputting an output current generated by the bridge circuit from the input current.