Inverter Subassemblies on Printed Circuit Board for Cooling
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing inverters for high power densities face complex manufacturing and maintenance challenges due to their intricate structure, which complicates troubleshooting and repair.
Innovation Solution
The electrical components of the DC-DC converter, intermediate circuit, and DC-AC converter are combined into subassemblies and arranged directly on a printed circuit board in a U-shaped manner, with the printed circuit board positioned on the heat sink, simplifying the structure and facilitating easy maintenance by allowing the entire board to be exchanged quickly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If electrical components are arranged in a distributed manner across multiple locations (heat sink, recesses, printed circuit board), then cooling efficiency is improved, but device complexity increases and maintenance becomes difficult
Solution Approach 1:
The patent combines multiple electrical components (DC-DC converter, intermediate circuit, DC-AC converter) onto a single printed circuit board, merging previously distributed components into one integrated assembly. This reduces structural complexity while maintaining functional separation through the U-shaped arrangement that optimizes cooling pathways.
2Temperature
If electrical components are distributed across multiple modular units, then cooling is optimized, but ease of repair deteriorates due to complex troubleshooting
Solution Approach 1:
The patent segments the inverter into two main functional units: a power electronics unit with the printed circuit board containing all electrical components, and a cooling unit with the heat sink. This segmentation allows the printed circuit board to be easily removed and replaced as a single module, simplifying maintenance while the U-shaped arrangement within the board maintains optimal cooling performance.
3Power
If components are arranged in a compact configuration, then power density increases, but manufacturing precision requirements increase
Solution Approach 1:
The printed circuit board serves multiple functions simultaneously: it provides structural support for all electrical components, acts as an electrical connection network, and functions as a mounting platform that interfaces with the heat sink for thermal management. This multi-functionality reduces the number of separate components needed, achieving compactness without proportionally increasing manufacturing precision requirements.
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 results in a compact, easily maintainable inverter with reduced troubleshooting time, improved cooling, and enhanced operational efficiency, particularly suitable for high power density applications like photovoltaic systems.
Implementation Method 1
the printed circuit board is arranged on the heat sink with the side opposite the component side, facing with its component side in the direction of the base of the basic shell of the housing
Implementation Method 2
the electrical components of the DC-DC converter, intermediate circuit and DC-AC converter are combined into subassemblies, and at least the DC disconnector as well the subassemblies of the DC-DC converter, intermediate circuit and DC-AC converter are arranged directly on the printed circuit board
Data Source
AI summary
An inverter for converting DC voltage into AC voltage, in particular a photovoltaic inverter for high power densities, in particular 250 W/dm3 to 500 W/dm3 power densities, has at least one DC input, an AC output, a heat sink, a printed circuit board, a DC disconnector, a DC-DC converter, an intermediate circuit, a DC-AC converter and a housing with a front cover and a basic shell. The electrical components of the DC-DC converter, intermediate circuit and DC-AC converter are combined into subassemblies. At least the DC disconnector and the subassemblies of the DC-DC converter, intermediate circuit and DC-AC converter are directly arranged on the circuit board in a U-shaped manner corresponding to the energy flow direction from DC input to AC output. The circuit board is arranged with the component side facing the base (65) of the basic housing shell and with the opposite side on the heat sink.