Power Conversion Device Stacked Module Layout
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Solution Overview
Problem
The existing power conversion devices for electric vehicles face challenges in reducing overall dimensions while maintaining performance and heat management, which hinders their scalability and efficiency.
Innovation Solution
The power conversion device features a converter module located between a base plate and a structural plate, with an auxiliary circuit board module positioned on the side of the structural plate, allowing for a closely stacked arrangement that reduces overall dimensions and enhances heat dissipation through strategic placement of magnetic elements and electronic components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the converter module and auxiliary circuit board module are arranged in a stacked configuration, then the overall dimensions of the power conversion device are reduced, but the heat dissipation management becomes more challenging
Solution Approach 1:
The patent transitions from a planar arrangement to a three-dimensional stacked configuration, placing the auxiliary circuit board module on the side of the structural plate away from the base plate. This vertical stacking reduces the horizontal footprint while managing heat through strategic spatial separation of thermal zones.
Solution Approach 2:
The patent applies different thermal management strategies to different regions: the converter module with magnetic elements is positioned for optimized heat dissipation, while the auxiliary circuit board module is placed in a location that minimizes thermal interference. Each module's positioning considers its specific heat generation characteristics and cooling requirements.
2Volume of moving object
If the converter module is positioned between the base plate and structural plate, then the device achieves compact form factor, but the electromagnetic interference control becomes more difficult
Solution Approach 1:
The patent divides the device into distinct functional modules: the converter module with magnetic elements is separated from the auxiliary circuit board module. This segmentation allows for targeted electromagnetic shielding and isolation strategies, with the structural plate serving as a natural barrier between the two modules.
Solution Approach 2:
The structural plate acts as an intermediary element between the converter module and auxiliary circuit board module. This intermediate structure provides both mechanical support and electromagnetic isolation, enabling compact stacking while maintaining electromagnetic compatibility through the mediating presence of the structural plate.
3Stability of the object's composition
If magnetic elements are fixed in accommodation spaces on the base plate, then the structural stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The base plate is designed with discrete accommodation spaces that individually house magnetic elements. This segmentation allows for modular assembly where magnetic elements can be independently positioned and secured, simplifying the manufacturing process while maintaining structural integrity through distributed fixation points.
Data Source
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AI summary
A power conversion device includes a casing, a structural plate, a converter module, an auxiliary circuit board module and a top cover. The casing includes a base plate and a side wall, and the base plate and the side wall form a chamber. The structural plate is located in the chamber. The converter module is located between the base plate and the structural plate. The auxiliary circuit board module is located at a side of the structural plate in the chamber away from the base plate, and is electrically connected with the converter module. The top cover seals the chamber.