Main Circuit Wiring Member with Intermediate Potential Layer
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Solution Overview
Problem
Conventional power conversion devices face limitations in downsizing due to the thickness of the busbar required for ensuring breakdown voltage, which restricts the thinning of the insulating layer between conductors.
Innovation Solution
A main circuit wiring member is designed with a conductor-insulating member configuration that includes intermediate-potential layer conductors sandwiched between conductors, allowing for enhanced insulation without increasing the thickness of the insulating layer, thereby enabling further downsizing while maintaining the required breakdown voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the thickness of the busbar is reduced to downsize the main circuit wiring member, then the size of the wiring member is reduced, but the breakdown voltage is insufficient
Solution Approach 1:
The patent divides the insulating structure into multiple segments: a conductor-insulating member covering each conductor and a conductor-to-conductor insulating member between conductors. This segmentation allows each insulating layer to be optimized independently, enabling thinner overall insulation while maintaining sufficient breakdown voltage through the combined insulation effect of multiple layers.
Solution Approach 2:
The patent applies different insulating structures to different locations: the conductor-insulating member provides insulation from the conductor surface, while the conductor-to-conductor insulating member provides enhanced insulation between adjacent conductors. This local differentiation allows optimization of insulation thickness in critical areas while reducing overall size.
2Volume of moving object
If the thickness of the insulating layer is reduced to downsize the busbar, then the size is reduced, but the insulation between conductors becomes insufficient
Solution Approach 1:
The insulation system is segmented into conductor-insulating members (covering individual conductors) and conductor-to-conductor insulating members (between conductors). This segmentation enables the conductor-to-conductor insulating member to be specifically optimized for inter-conductor insulation, allowing thinner overall insulation while maintaining sufficient breakdown voltage through the combined effect of multiple insulating layers.
Solution Approach 2:
The conductor-to-conductor insulating member acts as an intermediary element positioned between adjacent conductors. This intermediate insulating structure provides dedicated insulation protection between conductors, enabling reduced overall insulating layer thickness while maintaining sufficient insulation performance through the mediator's protective function.
Data Source
AI summary
A main circuit wiring member for electrically connecting a supply source of direct-current power and a semiconductor element module to each other or semiconductor element modules to each other, includes a first conductor covered with an insulating film and configured to allow a first potential to be applied thereto, a second conductor covered with the insulating film and configured to allow a second potential to be applied thereto, the second potential being lower than the first potential, and an insulating member that has intermediate-potential layer conductors sandwiched therein and is arranged between the first conductor and the second conductor.