Laminated Busbar Phase Module for Compact Vehicle Inverters
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Solution Overview
Problem
Existing vehicle inverters for powering significant loads, such as traction motors, are bulky and heavy due to the integration of capacitors and busbars, which occupy significant volume and weight, and generate excessive heat during operation.
Innovation Solution
A vehicle power system incorporating a phase module assembly with integrated laminated busbars and capacitors, utilizing insulated gate bipolar transistors to convert DC to multi-phase AC, reducing commutation inductance and enhancing power density while maintaining reliability and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional air-cooled inverter design with standalone capacitors and laminated bus structure is used, then reliable power conversion is achieved, but volume and weight increase significantly
Solution Approach 1:
The patent integrates capacitors directly into the inverter module structure, merging previously separate capacitor housing and busbar components into a unified assembly. This consolidation eliminates the need for separate capacitor mounting structures and reduces overall inverter volume while maintaining electrical reliability through optimized conductive connections between capacitors and power switches.
Solution Approach 2:
The inverter module structure is designed to serve multiple functions simultaneously: the housing provides mechanical support for capacitors, thermal management pathways, and structural integration with the vehicle power system. The busbar structure performs both electrical connection and mechanical support functions, reducing the need for separate mounting components and thereby reducing overall volume.
2Reliability
If traditional air-cooled inverter design with standalone capacitors and laminated bus structure is used, then reliable power conversion is achieved, but weight increases significantly
Solution Approach 1:
The integration of capacitors into the inverter module eliminates redundant structural components such as separate capacitor mounts and housing. By combining multiple functions into unified structures (e.g., the busbar serving both electrical and mechanical support roles), the overall material usage is reduced, thereby decreasing inverter weight while preserving electrical reliability through optimized connection designs.
3Power
If inverters power significant loads such as traction motors, then high power output is achieved, but heat generation increases excessively
Solution Approach 1:
The patent incorporates thermal management features that convert the harmful effect of heat generation into a beneficial cooling mechanism. The inverter module design includes thermal pathways that route heat away from power switches and capacitors, utilizing the heat flow itself to drive cooling air through the structure. This approach manages excessive heat generation effectively while maintaining high power output capability.
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
The system achieves a more compact and lightweight design, improving switching performance and reducing heat generation, thus optimizing power distribution for vehicles with high-power demands.
Implementation Method 1
one or more insulated gate bipolar transistors conductively coupled with the internal positive and negative terminal connectors and configured to convert the direct current into one phase of a multi-phase alternating current
Data Source
AI summary
A vehicle electrical power system includes a phase module assembly of a multi-phase inverter. The phase module assembly includes first and second flat laminated busbars extending in orthogonal planes. The phase module assembly also includes one or more transistors that convert direct current into one phase of a multi-phase alternating current of the multi-phase inverter, and to output the phase of the multi-phase alternating current to the load. The phase module assembly also includes one or more capacitors conductively coupled with the internal positive and negative terminal connectors and with the external positive and negative bushings configured to be conductively coupled with the power source of direct current. The assembly can be useful for vehicles because the components of the system are configured to carry large amounts of current in a more reliable and sustainable manner.