Gate Driver Connector for Modular Power Module Repair
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Solution Overview
Problem
Existing power conversion apparatuses face high repair costs due to the difficulty in separating and replacing only the faulty gate driver circuit component or power module when they fail, as they are often fixed together via soldering, requiring both to be replaced.
Innovation Solution
A power conversion apparatus design featuring a gate driver unit with a first substrate, a second substrate, and a connection member using a connector to connect the substrates, allowing for easy separation and potentially lower manufacturing costs, while maintaining effective operation of gate resistors near wide bandgap semiconductor switching elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the gate substrate and gate relay substrate are fixed to the gate control line by soldering, then the connection reliability is improved, but the ease of repair deteriorates because both components must be replaced when one fails
Solution Approach 1:
The gate driver unit is divided into separable components (gate substrate and gate relay substrate) that can be independently replaced. The connector enables electrical connection between substrates while allowing physical separation for repair purposes.
Solution Approach 2:
A connector is introduced as an intermediary component between the gate substrate and gate relay substrate. This connector provides reliable electrical connection during operation but allows easy disconnection for repair, mediating between the needs for both reliability and ease of repair.
2Ease of repair
If the gate substrate is separated from the power module, then the ease of repair is improved, but the connection reliability may deteriorate
Solution Approach 1:
The connector serves as a reliable intermediary that maintains stable electrical connection when substrates are separated for repair. It ensures that connection reliability is preserved even when the gate substrate is physically separated from the power module during maintenance operations.
3Ease of repair
If a connector is used to connect the gate substrate and gate relay substrate, then the ease of repair is improved, but the device complexity increases
Solution Approach 1:
The gate driver unit is segmented into separate components connected by a connector, enabling modular design. This segmentation allows the connector to be a standardized component rather than a custom complex connection structure, actually reducing overall system complexity while improving repairability.
Data Source
AI summary
A power conversion apparatus includes: a power module that converts an input of alternating current power into direct current (DC) power and outputs the DC power; and a gate driver unit that includes a first substrate having mounted thereon a gate driver circuit component that isolates a control signal input from a control apparatus, that converts the isolated control signal into a gate signal for driving the power module, and that outputs the gate signal, a second substrate that includes a wiring conductor fixed to a gate control terminal of the power module, and a connection member that includes a connector that connects the first substrate and the second substrate to each other.