Power Electronics Assembly with Mediated Control Connections
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Solution Overview
Problem
Existing power modules in power electronics are inflexible due to direct electrical connections with control circuit carriers, which restrict design flexibility and require early interface definition, leading to prolonged development times.
Innovation Solution
A component assembly comprising a power module, a separate connection module, and a control circuit carrier, where electrical connections are mediated through signal lines, allowing decoupling and flexibility in interface design and spatial arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If power modules are directly connected to control circuit carrier with press-fit pins or solder pins, then electrical connection is achieved, but design flexibility is restricted and development time is prolonged
Solution Approach 1:
The patent divides the direct connection between power module and control circuit carrier into two separate connection segments: first connection means between power module and intermediate connection element, and second connection means between intermediate connection element and control circuit carrier. This segmentation allows independent optimization and modification of each connection interface without affecting the other, thereby improving design flexibility while maintaining reliable electrical connection.
Solution Approach 2:
The patent introduces an intermediate connection element as a mediator between the power module and control circuit carrier. This intermediate element serves as a buffer that decouples the two components, allowing them to be independently designed and positioned. The intermediate connection element enables flexible routing of electrical connections through conductor tracks and connection points, resolving the contradiction between reliable connection and design flexibility.
2Reliability
If power modules are directly connected to control circuit carrier, then electrical connection is established, but interface definition must be made at early stage dominating development time
Solution Approach 1:
By segmenting the connection interface into two separate interfaces (power module to intermediate element, and intermediate element to control circuit carrier), the patent allows the interface design to be developed iteratively. The intermediate connection element serves as a stable reference point that can be designed early, while the other interfaces can be optimized later without requiring complete interface redefinition, thus reducing development time.
Solution Approach 2:
The intermediate connection element can be designed and positioned in advance as a preliminary action, establishing a stable connection framework early in development. This preliminary structure allows subsequent optimization of power module and control circuit carrier connections without requiring fundamental changes to the overall interface architecture, thereby reducing total development time while maintaining connection reliability.
3Reliability
If power module specifies installation space layout at early stage, then electrical connection is secured, but flexibility of power electronics design is restricted
Solution Approach 1:
The intermediate connection element acts as a mediator that decouples the installation space layout specification from the power module itself. The power module only needs to connect to the intermediate element, which can be positioned and routed flexibly within the housing. This allows the power module design to remain relatively simple while the intermediate element accommodates various spatial arrangements and routing configurations, thereby maintaining connection reliability while improving design flexibility.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement within the housing to resolve layout constraints. The intermediate connection element can be positioned at different locations and oriented in different directions, with conductor tracks routing through multiple dimensions. This dimensional flexibility allows the power module to maintain its electrical connection requirements while accommodating various power electronics design configurations without restriction.
Data Source
AI summary
A component assembly for power electronics, having at least one power module, at least one separate connection module, a separate control circuit carrier, and a housing. The at least one power module, the at least one connection module, and the separate control circuit carrier are arranged in a specified manner in the housing. The at least one power module is connected via first electrical signal lines to the at least one connection module and the at least one connection module is connected to the control circuit carrier via second electrical signal lines.