IPM Adapter PCB With Cross-Pin Layout and EMI Capacitors

Solution Overview

Problem

Existing motor controllers with integrated intelligent power modules (IPMs) face challenges in adapting to different IPM types due to varying pinouts and electromagnetic emission characteristics, necessitating costly and time-consuming redesigns to maintain compliance with EMI regulations.

Innovation Solution

An adapter circuit board with fixed interface contact pins and capacitors that allow seamless integration of different IPMs by providing a cross-pin configuration and electromagnetic interference reduction, without modifying the main circuit board, using capacitors to achieve target emission levels.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the main circuit board is redesigned to accommodate different IPM types, then adaptability improves, but development time and cost increase

Engineering Contradiction:

Improveadaptability to different IPM typesVSAvoiddevelopment time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The system is segmented into three independent parts: the main circuit board, the adapter circuit board, and the IPM module. The adapter circuit board acts as an intermediate layer that can be configured for different IPM types without modifying the main circuit board. This segmentation allows the adapter to bear the burden of adaptability while the main board remains stable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adapter circuit board serves as an intermediary component between the main circuit board and the IPM module. It provides pin configuration adaptation and EMI filtering capabilities, allowing different IPM types to interface with a standardized main board without requiring redesigns.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If the main circuit board is redesigned to accommodate different IPM types, then adaptability improves, but manufacturing cost increases

Engineering Contradiction:

Improveadaptability to different IPM typesVSAvoidmanufacturing cost

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The system is segmented into three independent parts: the main circuit board, the adapter circuit board, and the IPM module. The adapter circuit board acts as an intermediate layer that can be configured for different IPM types without modifying the main circuit board. This segmentation allows the adapter to bear the burden of adaptability while the main board remains stable.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The adapter circuit board is designed as a relatively simple, low-cost component compared to a full main board redesign. It can be easily manufactured and replaced if needed, providing an economical solution for supporting multiple IPM types.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Object-affected harmful factors

If capacitors are added to reduce radiated emission, then EMI compliance improves, but device complexity increases

Engineering Contradiction:

Improveradiated emission levelVSAvoidcircuit board complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The adapter circuit board serves as an intermediary component between the main circuit board and the IPM module. It provides pin configuration adaptation and EMI filtering capabilities, allowing different IPM types to interface with a standardized main board without requiring redesigns.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The EMI filtering capability is achieved by adjusting capacitor parameters (capacitance values, placement positions) on the adapter circuit board rather than redesigning the entire system. This allows optimization of radiated emission levels through parameter tuning of filtering components.

Inventive Principle:

Principle #35Parameter changes

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

Enables quick adaptation to different IPMs, maintaining electromagnetic compatibility without requalifying the entire product, allowing cost-effective and efficient integration and interference reduction.

Implementation Method 1

comprises a set of capacitors connecting points on the adapter circuit board and capacitors connected to at least some of said capacitors connecting points and configured to reduce a radiated emission level of the motor controller

Methodology Applied

Scientific EffectCapacitance: Capacitance

Data Source

PatentUS12470111B2Apparatus for adapting a power module to the printed circuit board of a motor controller

Publication Date: 2025.11.11 SCHNEIDER TOSHIBA INVERTER EUROPE SAS

AI summary

An apparatus for adapting an intelligent power module to a main circuit board of a motor controller, including: an adapter circuit board having fixed interface contact pins configured to be plugged into interface contact elements of the main circuit board of the motor controller, the power module having contact pins having a first pin out configuration connected on the adapter circuit board, wherein the adapter circuit board provides a cross pin configuration between the first pin out configuration of the power module and the interface contact pins having a second pin out configuration in order to connect the power module to the main circuit board, a set of capacitors connecting points on the adapter circuit board and capacitors connected to at least some of the capacitors connecting points and configured to reduce a radiated emission level of the motor controller, the capacitance of the capacitors being designed to reach a target threshold for the radiated emission level of the motor controller.