Power Converter Bus Bar Layout for Lower EMC Noise Currents
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Solution Overview
Problem
Power converters in vehicles face increased electromagnetic compatibility (EMC) noise due to the close proximity of high-voltage capacitor circuit units and low-voltage control circuit units, requiring enhanced safeguard measures to prevent malfunction.
Innovation Solution
A power converter design where the control circuit board is separated from the capacitor and connected via a connection conductor that extends around an electrical conductor grounded to the base, reducing stray capacitance between bus bars and the control circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the control circuit board is disposed close to the capacitor and power module, then the device complexity is reduced and space is saved, but the electromagnetic compatibility (EMC) noise current flowing through the control circuit board increases
Solution Approach 1:
The patent introduces a base as an intermediary component between the control circuit board and the capacitor/power module. The base provides electrical connection while spatially separating the control circuit board from the high-voltage components, thereby reducing EMC noise current without significantly increasing device complexity
Solution Approach 2:
The patent utilizes the stacking dimension (vertical arrangement) to separate components. The control circuit board is placed on the base while the capacitor and power module are arranged in different spatial positions, using the third dimension to reduce electromagnetic interference while maintaining compact overall structure
2Object-affected harmful factors
If the control circuit board is disposed apart from the capacitor, then the electromagnetic compatibility (EMC) noise current is reduced, but the device complexity increases and space requirement increases
Solution Approach 1:
The patent merges the base with the connection conductor structure, where the base serves both as a mechanical support for the control circuit board and as an electrical connection element. This integration reduces the number of separate components and simplifies the overall structure while maintaining the noise reduction benefit
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 design effectively reduces EMC noise currents flowing through the control circuit board, enhancing the safeguard against malfunctions by minimizing capacitive coupling and increasing the path impedance for noise currents.
Implementation Method 1
a capacitor that smooths DC power and supplies the DC power to the power conversion circuit unit
Implementation Method 2
an electrical conductor electrically connected to the base and extending in a stacking direction in which the base and the control circuit board are stacked
Implementation Method 3
The connection conductor extends around the electrical conductor and is connected to the semiconductor module... reduce stray capacitance between the positive and negative-side bus bars and the control circuit board
Data Source
AI summary
Provided is a power converter that allows a reduction in EMC noise current flowing through a control circuit board. A power converter 1 includes a semiconductor module 52, a capacitor 51, a control circuit board 45a, positive and negative-side bus bars 41, 42 connecting the semiconductor module 52 and the capacitor 51, a base 33 electrically connected to a ground of the control circuit board 45a, the control circuit board 45a being placed on the base 33, and an electrical conductor 35 electrically connected to the base 33 and extending in a stacking direction in which the base 33 and the control circuit board 45a are stacked. The positive and negative-side bus bars 41, 42 extend around the electrical conductor 35 and are connected to the semiconductor module 52.