Power Converter Capacitor Layout for Compact Design
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Solution Overview
Problem
Conventional power converters require long connecting members to connect the capacitor to the dc power supply, increasing production costs and the overall size due to the capacitor's placement relative to the semiconductor stack.
Innovation Solution
The capacitor is positioned adjacent to the semiconductor stack in the direction of module stacking, with the input terminal table located near the end of the capacitor opposite the power terminals, reducing the need for long connectors and allowing for a more compact design, including a frame and holding beams to enhance stability and vibration resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the capacitor is positioned away from the semiconductor stack in the Z-direction, then the capacitor can be easily connected to the DC power supply, but the length of connecting members increases, leading to increased production cost and overall device size
Solution Approach 1:
The patent repositions the capacitor from a location away from the semiconductor stack (Z-direction) to a location adjacent to the semiconductor stack in the X-direction (stacking direction). This dimensional change allows the capacitor to be closely integrated with the semiconductor stack while maintaining easy connection to the DC power supply through the bus bars, thereby reducing the length of connecting members and overall device size without compromising ease of manufacture
2Ease of manufacture
If the capacitor is positioned away from the semiconductor stack, then connection to DC power supply is simplified, but the length of connecting members increases, leading to increased production cost
Solution Approach 1:
The patent merges the capacitor's position with the semiconductor stack by placing it adjacent to the stack in the stacking direction. This integration allows the capacitor to share the same compact space as the semiconductor modules, reducing the need for long connecting members and minimizing material usage. The simplified layout reduces production cost while maintaining ease of connection through the bus bar structure
3Adaptability or versatility
If long connecting members are used to connect the capacitor to the DC power supply, then the capacitor can be positioned away from the semiconductor stack, but the amount of metal material used increases
Solution Approach 1:
The patent applies local quality by positioning the capacitor adjacent to the semiconductor stack in the stacking direction, creating a localized compact arrangement. This placement minimizes the distance between the capacitor and the bus bars, thereby reducing the amount of metal material needed for connecting members. The layout flexibility is maintained through the modular semiconductor stack structure, allowing the capacitor to be integrated without compromising adaptability
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
This configuration decreases the size and production cost of the power converter while improving vibration resistance by minimizing material usage and optimizing the layout of components.
Implementation Method 1
a plurality of cooling paths, each of the semiconductor modules including a main unit in which semiconductor devices are mounted and power terminals which extend from the semiconductor module, the cooling paths having a cooling medium flowing therethrough to cool the semiconductor modules
Implementation Method 2
a capacitor including a first and a second bus bar connector terminal connected to the positive bus bar and the negative bus bar, respectively, and a first and a second input terminal connected to the dc power supply, the capacitor working to smooth dc voltage developed between the positive bus bar and the negative bus bar
Data Source
AI summary
A power converter equipped with a semiconductor stack made up of semiconductor modules, bus bars coupled to power terminals of the semiconductor modules, a capacitor, and an input terminal table. The capacitor is disposed in alignment with a first direction in which the semiconductor modules are stacked. The capacitor has a first end and a second end opposed to the first end in a second direction in which the power terminals extend from the semiconductor modules. The first end faces in the second direction. The input terminal table is located near the second end of the capacitor. This structure permits the power converter to be reduced in size and produced at a decreased cost.