Mold Bus Bar Terminal Orientation for Power Conversion Reliability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The connection reliability of terminals in power conversion devices for high-power vehicle drive motors is inadequate, and there is a need for improved assembling performance.
Innovation Solution
A power conversion device with a power semiconductor module, a capacitor module, and a mold bus bar sealed with a resin material, where the terminals are arranged such that their main surfaces face in the same direction, enhancing electrical connections and reducing inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional conductor members are connected to power semiconductor modules and capacitor modules, then power conversion is achieved, but connection reliability of terminals is insufficient
Solution Approach 1:
The patent combines multiple conductor members (bus bars) into a single integrated mold bus bar structure that simultaneously connects to the power semiconductor module and capacitor module. This merging of separate connection components into one unified structure improves terminal connection reliability while simplifying the overall connection structure, directly resolving the technical contradiction between connection reliability and device complexity.
Solution Approach 2:
The mold bus bar acts as an intermediary component that mediates the electrical connection between the power semiconductor module and capacitor module. By introducing this intermediate connector with standardized terminals, the patent enhances connection reliability through improved contact interfaces while maintaining manageable structural complexity.
2Reliability
If terminals are connected with complex structures to improve reliability, then connection reliability improves, but assembling performance deteriorates
Solution Approach 1:
The mold bus bar is segmented into distinct terminal portions (first terminal for power semiconductor module, second and third terminals for capacitor module) with clearly defined connection interfaces. This segmentation allows each terminal to be independently optimized for reliable connection while maintaining ease of assembly through modular installation, resolving the contradiction between reliability and assembling performance.
Solution Approach 2:
The terminals of the mold bus bar are pre-formed and pre-positioned in the resin material with predetermined orientations. This preliminary preparation of connection interfaces enables reliable terminal connections to be achieved without complex assembly operations, thereby improving both connection reliability and assembling performance simultaneously.
3Adaptability or versatility
If terminals are arranged without standardized orientation, then connection flexibility is maintained, but variations in junctions increase
Solution Approach 1:
The mold bus bar employs asymmetric terminal arrangement where the first terminal and second/third terminals have different geometries and orientations optimized for their specific connection targets. The main surfaces of terminals are deliberately oriented in standardized directions to reduce junction variations, while the asymmetric design maintains the necessary connection flexibility for different module configurations.
Data Source
AI summary
It is an object of the present invention to enhance connection reliability of terminals while enhancing assembling performance. A power conversion device according to the present invention includes: a power semiconductor module having a power terminal; a capacitor module for supplying smoothed power to the power semiconductor module; and a mold bus bar in which a conductor part for electrically connecting the power semiconductor module and the capacitor module is sealed by a resin material, wherein the capacitor module has a positive capacitor terminal and a negative capacitor terminal, the power terminal, the positive capacitor terminal, and the negative capacitor terminal are formed such that the main surfaces of the terminals face in the same direction, and the mold bus bar has a first terminal contacting with the main surface of the power terminal, a second terminal contacting with the main surface of the positive capacitor terminal, and a third terminal contacting with the main surface of the negative capacitor terminal.