PCB Power Cell Reducing DC Bus Inductance
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Solution Overview
Problem
Current multi-cell power supplies have high DC bus inductance due to the physical placement of separate parts, leading to increased stress on semiconductor devices and lower utilization of device ratings, as well as labor and cost inefficiencies in assembly.
Innovation Solution
A printed circuit board (PCB) power cell design that integrates a DC bus, capacitors, high wattage resistors, and a power module with a heat sink, allowing for a three-phase AC input to be converted to a single-phase AC output, thereby reducing DC bus inductance and simplifying the assembly process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate parts are used to construct the DC bus and connect semiconductor power modules, then the power cell can be assembled with standard components, but the DC bus inductance increases and assembly time increases
Solution Approach 1:
The patent combines the DC bus and semiconductor power module interconnections into a single integrated PCB assembly. The PCB serves as both the structural support and the electrical connection medium, merging functions that were previously performed by separate bus bars and mounting hardware. This integration reduces the number of discrete parts and assembly steps while minimizing inductance through optimized trace routing.
Solution Approach 2:
The patent replaces traditional mechanical bus bar connections with PCB-based electrical connections. Instead of using separate mechanical components (bus bars, brackets, fasteners) to connect the DC bus to power modules, the PCB provides both mechanical support and electrical connectivity through its copper traces and mounting structure, eliminating the need for additional mechanical connection elements.
2Reliability
If separate parts are used to construct the DC bus, then components can be individually selected and replaced, but the physical placement leads to large DC bus inductance
Solution Approach 1:
The patent merges the DC bus structure with the PCB substrate itself. The DC bus traces are routed directly on the PCB, eliminating the need for separate bus bar components. The power modules are mounted directly to the PCB and electrically connected through PCB traces, integrating multiple functions into a single structural platform and reducing overall inductance.
Solution Approach 2:
The PCB serves multiple functions simultaneously: it provides mechanical support for all components, acts as the DC bus conductor, provides electrical interconnections between power modules and capacitors, and serves as the mounting structure for the entire power cell assembly. This multi-functionality reduces the total number of components needed.
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 PCB power cell design reduces DC bus inductance, decreases labor and cost associated with assembly, and enhances reliability by minimizing circuit parasitics and errors, resulting in consistent performance and reduced stress on semiconductor devices.
Implementation Method 1
a heat sink configured to dissipate heat generated by the power module
Implementation Method 2
a heat sink configured to dissipate heat generated by the power module
Data Source
AI summary
A printed circuit board power cell having a printed circuit board including a DC bus disposed within the printed circuit board. The printed circuit board power cell includes a plurality of capacitors connected to the DC bus, a three-phase AC input disposed on the printed circuit board and a single-phase AC output disposed on the printed circuit board. The printed circuit board power cell also includes a power module connected to the DC bus, the three-phase AC input and the single-phase AC output, wherein the power module receives three phase AC input power via the three-phase AC input and responsively outputs a single-phase AC power via the single-phase AC output.