Partitioned Power Converter Busbar Layout for Compact Cooling
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Solution Overview
Problem
Conventional power converters require a large area for accommodating electrical components due to busbars penetrating through the partition wall, leading to inefficient use of space and cooling challenges.
Innovation Solution
A power converter design with a partitioned casing that includes a through busbar penetrating the partition wall at a single location, allowing for compact arrangement of components and improved cooling by aligning busbars with a cooling passage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple busbars penetrate through the partition wall at separate locations, then electrical connection between chambers is achieved, but the internal dimensions of the casing increase and space utilization deteriorates
Solution Approach 1:
The patent combines multiple separate busbar penetration locations into a single integrated penetration point in the partition wall. Multiple busbars are routed through this single location, merging what would have been separate penetration points into one unified structure. This reduces the overall footprint and internal dimensions of the casing while maintaining all necessary electrical connections between chambers.
Solution Approach 2:
The patent arranges busbars to extend in different spatial dimensions from the single partition wall penetration point. Instead of requiring separate penetration points distributed across the partition wall surface, the busbars are routed through one location and then extend in various directions within the chambers, utilizing three-dimensional space efficiently.
2Temperature
If busbars are positioned away from cooling passages, then electrical connection is maintained, but cooling efficiency deteriorates
Solution Approach 1:
The patent positions busbars with different thermal characteristics at different locations relative to cooling passages. High-current busbars that generate more heat are placed in closer proximity to cooling passages, while lower-current busbars are positioned accordingly. This local optimization of thermal management addresses the specific cooling needs of different busbars based on their electrical load characteristics.
Solution Approach 2:
The patent utilizes the third dimension (vertical or depth direction) to route busbars alongside cooling passages without requiring complex lateral rearrangements. By extending busbars in multiple dimensions from the single partition penetration point, the design achieves effective thermal coupling while maintaining electrical connection functionality.
3Adaptability or versatility
If busbars are arranged in extended paths, then electrical connection flexibility is improved, but inductance increases
Solution Approach 1:
The patent minimizes inductance by routing busbars in straight lines along the shortest possible paths from the single partition wall penetration point to their destination terminals. By utilizing three-dimensional routing options, the design achieves direct connection paths that reduce loop area and inductance, while still providing connection flexibility for different component configurations.
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
Reduces the internal dimensions of the casing, enhances cooling efficiency, and minimizes inductance by arranging busbars close to the cooling passage, thus optimizing space utilization and thermal management.
Implementation Method 1
A cooling passage is formed in the partition wall and allows cooling water to flow therethrough
Data Source
AI summary
An electric power converter includes a casing that defines first and second chambers separated by a partition wall. Semiconductor devices in the first chamber form a power conversion circuit and are electrically connected to a smoothing capacitor positioned in the first chamber. A noise filter is disposed in the second chamber and is electrically connected to the smoothing capacitor. The partition wall includes a cooling passage that permits flow of cooling water. A connecting busbar extends between the first and second chambers as part of a power path that links a terminal of the noise filter and terminals of the semiconductor devices. The connecting busbar includes a through portion that extends between the chambers within the casing and penetrates the partition wall.