Power Converter Substrate Routing for Flexible Connector Layout
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Solution Overview
Problem
Repositioning of connectors in power converters often requires significant design modifications, leading to time and cost losses due to the need for changes in internal component layouts and busbar arrangements.
Innovation Solution
The power converter incorporates conductive patterns formed on a substrate, allowing for flexible repositioning of connectors by modifying these patterns rather than busbars, thereby simplifying design modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If connectors are repositioned in conventional power converters, then connector positioning flexibility is improved, but design modification complexity increases due to required changes in internal component layouts and busbar arrangements
Solution Approach 1:
The invention divides the connection system into modular components: a substrate with conductive patterns, a cooler with cooling fins, and connectors that can be independently positioned. The substrate serves as a flexible intermediary that can accommodate different connector positions without requiring changes to the overall structural layout, thereby reducing design modification complexity while maintaining positioning flexibility.
Solution Approach 2:
The substrate acts as an intermediary element between the connectors and the cooler. It provides conductive patterns that can be routed to accommodate various connector positions, decoupling the connector positioning from the cooler structure. This intermediary allows connector repositioning without requiring complex modifications to internal component layouts.
2Adaptability or versatility
If connectors are repositioned with conventional busbar arrangements, then adapter positioning flexibility is improved, but time and cost losses increase due to required redesign of busbar layouts
Solution Approach 1:
The invention replaces the conventional mechanical busbar arrangement with conductive patterns formed on a substrate. These conductive patterns can be more easily modified or rerouted compared to rigid busbars, reducing the time and cost associated with redesign when connector positions need to be changed.
3Adaptability or versatility
If connectors are repositioned with conventional busbar arrangements, then adapter positioning flexibility is improved, but cost losses increase due to required redesign of busbar layouts
Solution Approach 1:
The invention replaces expensive and difficult-to-modify busbars with conductive patterns on a substrate, which are easier and more cost-effective to redesign. This substitution maintains adapter positioning flexibility while significantly reducing the costs associated with manufacturing modifications.
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 approach enables flexible handling of design changes due to connector repositioning, reducing the time and cost associated with redesigning internal components and busbar layouts.
Implementation Method 1
a cooler for cooling the plurality of switching elements
Data Source
AI summary
A power converter includes a capacitor and a substrate on which a plurality of switching elements for power conversion are mounted. The power converter includes a cooler for cooling the plurality of switching elements and a housing that accommodates the capacitor, the substrate, and the cooler. The power converter includes a power connector exposed from the housing and an output connector exposed from the housing. The power converter includes a plurality of lines that include a plurality of power lines each electrically connected to the capacitor, given switching elements, and the power connector. The plurality of lines include a plurality of output lines each electrically connected to given switching elements and the output connector. At least one among the plurality of lines is a line that includes a conductive pattern formed on the substrate.