Integral Bus Bar for Power Converter
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Solution Overview
Problem
Existing power converters with semiconductor modules and bus bars face high manufacturing costs, complex assembly, and increased wiring resistance and inductance due to the branching of bus bars to connect multiple semiconductor modules.
Innovation Solution
The power converter employs integrally formed connecting bus bars with alternating terminal connecting sections and connecting sections, eliminating the need for branching and allowing for a simpler shape, reducing manufacturing costs and assembly complexity while minimizing wiring resistance and inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bus bars are branched off to connect power terminals of multiple semiconductor modules, then connectivity is achieved, but the shape becomes complicated and manufacturing cost increases
Solution Approach 1:
The bus bar extends in the stacking direction (vertical dimension) to connect power terminals of multiple semiconductor modules stacked vertically. This dimensional arrangement eliminates the need for lateral branching, simplifying the bus bar shape while maintaining connectivity to all modules.
2Reliability
If bus bars are folded or bent in various directions to connect terminals, then connectivity is achieved, but narrow width portions are formed increasing wiring resistance and inductance
Solution Approach 1:
The bus bar utilizes the stacking direction (vertical dimension) to reach multiple terminals, maintaining a constant width in the horizontal plane. This eliminates narrow sections that would increase resistance and inductance, while still achieving connectivity to all semiconductor modules through vertical extension.
3Ease of manufacture
If integrally formed bus bars are used without branching, then manufacturing cost is reduced, but connectivity to multiple terminals must be maintained
Solution Approach 1:
The integral bus bar structure extends vertically in the stacking direction to connect multiple semiconductor modules without requiring lateral branches. This single continuous piece maintains electrical connectivity to all modules while simplifying manufacturing and eliminating the need for complex branching configurations.
Data Source
AI summary
A power converter includes a plurality of semiconductor modules that have main body sections, each of the main body sections has a semiconductor element therein, and power terminals projected from the main body sections, and a plurality of bus bars that connect the power terminals of the semiconductor modules. At least one of the plurality of the bus bars are connecting bus bars which have a plurality of terminal connecting sections that connect the power terminals of the plurality of different semiconductor modules, and connecting sections that connect the terminal connecting sections. The entirety of each of the connecting bus bars is formed integrally. The terminal connecting sections and the connecting section of every connecting bus bar are provided alternately in the connecting bus bar, and disposed in substantially the same position in a projecting direction of the power terminals.