Hybrid Busbar and PCB Conductive Pattern for Power Conversion
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Solution Overview
Problem
Conventional power conversion devices require larger busbars to increase current-carrying capacity, leading to increased costs and unnecessary component mounting, especially when different models with varying current-carrying capacities use common printed wiring boards.
Innovation Solution
A power conversion device with a conductive pattern on a printed wiring board that includes a busbar with a plate-like shape overlapping the conductive pattern, allowing current to be split and reducing heat dissipation, enabling a configuration that matches the required current-carrying capacity without unnecessary components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a busbar is used as a wiring member to increase current-carrying capacity, then heat generation is suppressed, but cost is inevitably increased due to larger busbar size
Solution Approach 1:
The patent combines the busbar and conductive pattern into a hybrid current-carrying structure. The busbar provides low-impedance current paths where needed, while the conductive pattern on the printed wiring board handles less critical current flow. This merging allows the system to achieve adequate current-carrying capacity and heat dissipation without requiring an oversized busbar, thus reducing cost while maintaining temperature control.
Solution Approach 2:
The conductive pattern on the printed wiring board serves dual functions: it provides electrical connection between components and acts as an auxiliary current-carrying path. This multi-functionality reduces reliance on the busbar alone, allowing for smaller busbar dimensions and lower cost while still managing heat generation effectively.
2Reliability
If a busbar is provided on a common printed wiring board for all models, then current-carrying capacity is ensured, but cost is inevitably increased due to mounting of unnecessary components in models with small current-carrying capacity
Solution Approach 1:
The patent enables dynamic configuration adaptation by making the busbar optional or variable based on model requirements. Models with small current-carrying capacity can omit the busbar or use a reduced busbar configuration, while models requiring higher capacity include the full busbar structure. This dynamic approach allows a single printed wiring board design to serve multiple models without incurring costs for unnecessary components in low-power models.
Solution Approach 2:
The conductive pattern is designed with varying local properties - some areas have thicker traces or additional copper layers to handle higher current densities, while other areas use standard trace widths. This local quality variation allows the printed wiring board to provide adequate current-carrying capacity in specific regions without requiring a busbar throughout the entire board, reducing overall cost for models with modest power requirements.
3Temperature
If a larger busbar is used to increase current-carrying capacity, then temperature increase is suppressed, but device size is increased
Solution Approach 1:
The patent utilizes the two-dimensional plane of the printed wiring board by integrating conductive patterns that spread current flow across the board surface. This dimensional utilization allows the current path to extend laterally rather than requiring increased busbar thickness or length, effectively managing heat generation without increasing the vertical profile or overall device volume.
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 allows for cost-effective current-carrying capacity adjustment, reduces heat dissipation, and enables downsizing of the device while maintaining efficient cooling and modularization.
Implementation Method 1
a conductive pattern to electrically connect the alternating-current power-supply input part, the converter circuit part, the inverter circuit part, and the alternating-current power-supply output part to one another
Implementation Method 2
measures against heat generation that occurs when a current is made to flow in the printed wiring board
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
A power conversion device (50) includes a printed wiring board (7) on which an alternating-current power-supply input part (9) to which alternating-current power is input, a converter circuit part to convert alternating-current power input to the alternating-current power-supply input part (9) to direct-current power, an inverter circuit part to convert direct-current power converted by the converter circuit part to alternating-current power, an alternating-current power-supply output part to output alternating-current power converted by the inverter circuit part, and a conductive pattern (6) to electrically connect the alternating-current power-supply input part (9), the converter circuit part, the inverter circuit part, and the alternating-current power-supply output part to one another are provided, and a busbar (1) that has a plate-like shape with a plane direction thereof perpendicular to a plane direction of the printed wiring board (7), is arranged to overlap the conductive pattern (6) in plan view, and includes two or more connecting portions that are in contact with the conductive pattern (6).