Power Converter Thermal Shielding for Control Circuit Protection
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Solution Overview
Problem
Conventional power converters with a discharging resistor mounted on the control circuit board are prone to thermal damage, leading to malfunction due to heat radiation, and require additional space if the resistor is mounted in a casing, increasing the converter's size.
Innovation Solution
A power converter design with a discharging resistor mounted on the control circuit board, where a driver is placed between the timing controller, power supply circuit, and the discharging resistor to act as a thermal shield, minimizing heat exposure and eliminating the need for additional space, thus reducing the overall size while enhancing cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the discharging resistor is mounted on the control circuit board, then the overall size of the power converter is reduced, but the control circuit board may be thermally damaged by heat from the discharging resistor
Solution Approach 1:
A heat-resistant substrate material is introduced as an intermediary between the discharging resistor and the control circuit board. This substrate acts as a thermal barrier that blocks heat transmission from the discharging resistor to the control circuit board, while still allowing the compact mounting arrangement to be maintained.
Solution Approach 2:
The thermal properties of the substrate material are changed by selecting a material with high heat resistance and low thermal conductivity. This parameter change allows the substrate to withstand the high temperatures generated by the discharging resistor while protecting the control circuit board from thermal damage.
2Object-affected harmful factors
If the discharging resistor is mounted in the housing to reduce heat exposure, then thermal damage risk is reduced, but additional space is required increasing the converter size
Solution Approach 1:
The housing structure and the heat shielding function are merged into a single integrated component. The housing is designed to serve both as the structural enclosure and as a thermal barrier, eliminating the need for separate heat shielding components and additional space.
Solution Approach 2:
The housing is given multiple functions: it serves as the structural enclosure for the power converter and simultaneously acts as a heat shield to protect the control circuit board from thermal damage. This multi-functionality eliminates the need for separate protective components.
3Productivity
If the discharging resistor is positioned close to the cooling device, then cooling efficiency is improved, but heat exposure to surrounding components increases
Solution Approach 1:
The heat-resistant substrate material is applied locally at the position where the discharging resistor is mounted on the control circuit board. This localized application provides thermal protection precisely where needed, allowing the discharging resistor to be positioned close to the cooling device for improved cooling efficiency without exposing surrounding components to excessive heat.
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
The design effectively protects critical components from thermal damage, maintains a reduced size by eliminating the need for extra space, and improves cooling efficiency by positioning the discharging resistor close to the cooling device.
Implementation Method 1
Upon discharging of the smoothing capacitor 95, the electric current flows through the discharging resistor 96 mounted on the control circuit board 93, heating it.
Implementation Method 2
a cooling device which works to cool the semiconductor modules
Implementation Method 3
a cooling device which works to cool the semiconductor modules
Data Source
AI summary
A power converter equipped with a plurality of semiconductor modules, a cooling device, a control circuit board, a smoothing capacitor, and a discharging resistor. The discharging resistor mounted on the control circuit board in parallel connection to the smoothing capacitor. The control circuit board has fabricated thereon a timing controller working to control timings of on/off operations of the semiconductor modules, a driver coupled to control terminals of the semiconductor modules to control voltage applied to the control terminals, and a power supply circuit working to transform a voltage input to the control circuit board into operating voltages for the timing controller and the driver. The driver is disposed between at least one of the timing controller and the power supply circuit and the discharging resistor, thereby protecting the timing controller and/or the power supply circuit mounted on the control circuit board from thermal energy radiating from the discharging resistor.