Power Conversion System PCB Busbar Replacement
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Solution Overview
Problem
The existing power conversion systems (PCS) in energy storage systems face space constraints due to the dominance of battery cells, leading to a small size and inefficient layout, with copper busbars occupying significant space, complicating the arrangement of other functional boards and causing heat dissipation issues.
Innovation Solution
A power conversion system design that replaces copper busbars with a target PCB, using copper pillars for electrical connections, allowing for a stacked layout of components, separate high-voltage and low-voltage compartments, and enhanced ventilation and cooling systems to improve space utilization and heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If copper busbars are used for electrical connections, then electrical conductivity is ensured, but space occupancy increases and layout complexity increases
Solution Approach 1:
The patent extracts the copper busbar from the system and replaces it with a PCB-based connection structure. The PCB with copper pillars provides the necessary electrical connectivity while occupying significantly less space, thus resolving the contradiction between ensuring electrical conductivity and reducing space occupancy.
Solution Approach 2:
The patent replaces the mechanical copper busbar connection system with an integrated PCB electrical connection system. The PCB structure with surface-mounted inductors and copper pillars provides equivalent or superior electrical connectivity while enabling compact stacking layouts, thereby reducing both space occupancy and layout complexity.
2Reliability
If copper busbars are used for electrical connections, then electrical connectivity is achieved, but layout of functional boards becomes difficult
Solution Approach 1:
The patent merges the electrical connection function and the structural support function into a single PCB assembly. The PCB integrates the connection structure, inductor mounting, and functional board support, eliminating the need for separate copper busbars and simplifying the overall layout process.
Solution Approach 2:
The PCB assembly serves multiple functions simultaneously: it provides electrical connectivity through copper pillars, supports inductors through surface-mount technology, serves as a structural platform for functional boards, and enables compact stacking arrangements. This multi-functionality resolves the layout complexity issue while maintaining electrical connectivity.
3Area of stationary object
If compact layout is implemented to reduce size, then space utilization improves, but heat dissipation becomes insufficient
Solution Approach 1:
The patent transitions from a planar layout to a three-dimensional stacked architecture. Functional boards are stacked vertically on the PCB assembly, utilizing the vertical dimension for space utilization while maintaining adequate horizontal spacing and ventilation channels for heat dissipation. This dimensional transition resolves the contradiction between compact layout and heat dissipation.
Solution Approach 2:
The PCB assembly acts as an intermediary structure that enables both compact stacking and effective heat dissipation. The stacked configuration maximizes space utilization, while the PCB design incorporates thermal management features such as ventilation channels and heat sinks that facilitate heat dissipation despite the compact arrangement.
4Area of stationary object
If stacked layout is used to reduce space, then space occupancy decreases, but ventilation and cooling become challenging
Solution Approach 1:
The patent segments the PCS into distinct stacked modules (input compartment, output compartment, power conversion control compartment), each with dedicated ventilation channels. This segmentation allows independent heat dissipation paths for each module, preventing heat accumulation while maintaining compact overall dimensions.
Solution Approach 2:
The PCB assembly serves as an intermediary structure that enables both compact stacking and effective heat dissipation. The stacked configuration maximizes space utilization, while the PCB design incorporates thermal management features such as ventilation channels and heat sinks that facilitate heat dissipation despite the compact arrangement.
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 new design reduces space occupancy, enhances heat dissipation, and improves reliability by preventing component encroachment and cooling air blockage, thus increasing efficiency and safety.
Implementation Method 1
a first cooling fan group is disposed in the lower space of the output compartment
Implementation Method 2
a heat sink is further disposed in the lower space of the power conversion control compartment, and the power board is located above the heat sink
Data Source
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AI summary
The present application relates to the field of energy storage system technologies, and in particular, to a power conversion system (PCS), an energy storage system, and an electric device. The PCS is applied to an energy storage system, and includes a cabinet. The cabinet is provided with an output compartment and a power conversion control compartment. The output compartment includes a plurality of output connection ports formed on a front panel of the cabinet. The power conversion control compartment includes a power board, a plurality of inductors, an AC output board, and a target printed circuit board (PCB). The target PCB is respectively connected to the power board, the plurality of inductors, and the AC output board.