Power Converter Insulating Plate Laser Welding
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Solution Overview
Problem
In power converters with a stacking unit, the narrow alignment of semiconductor module terminals makes laser welding challenging, and there is a risk of damage from inadvertently reflected laser beams hitting the stacking unit.
Innovation Solution
The power converter design includes an insulating plate with cylinder portions that absorb the reflected laser beam by being colored to match the wavelength, reducing damage from the reflected beam during welding of terminals and bus bar branch portions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser beam is used for welding terminals and bus bar in narrow spacing, then welding precision is improved, but risk of damage from reflected beam increases
Solution Approach 1:
The patent applies this principle by designing the insulating plate with a reflective surface that redirects the harmful reflected laser beam away from the stacking unit. The insulating plate converts the harmful reflected beam into a beneficial controlled reflection path, directing it toward a safe area without damaging components. This resolves the contradiction by maintaining laser welding precision while eliminating the damage risk through intentional beam redirection.
2Object-affected harmful factors
If tips of terminals and branch portions are extended and inclined to redirect reflected beam, then damage risk is reduced, but device complexity increases
Solution Approach 1:
The patent extracts the beam redirection function from the terminals and bus bar structure itself, and places it on a separate insulating plate component. Instead of modifying the terminals and branch portions to be extended and inclined (which would increase device complexity), the solution separates the harm mitigation function into an independent element - the insulating plate with its specifically designed reflective surface. This resolves the contradiction by reducing damage risk without complicating the electrical connection structure.
3Object-affected harmful factors
If insulating plate with cylinder portions is used to redirect reflected beam, then damage from reflected beam is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent merges the insulating plate function with the laser beam redirection function into a single integrated component. The insulating plate simultaneously provides electrical insulation between the positive and negative bus bars and redirects the reflected laser beam through its reflective surface. This dual-function design resolves the contradiction by reducing damage risk without requiring additional separate components, thereby maintaining ease of manufacture.
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 damage from reflected laser beams during the welding process by ensuring that most of the reflected beam is reflected or absorbed by the insulating plate, preventing overheating of components.
Implementation Method 1
The insulating plate with cylinder portions that absorb the reflected laser beam by being colored to match the wavelength
Implementation Method 2
Laser beam is suitable for welding in a narrow spot
Data Source
AI summary
A power converter may be provided with: a stacking unit including semiconductor modules interposed between adjacent coolers; a capacitor disposed next to the stacking unit; a first bus bar; a second bus bar; and an insulating plate. The insulating plate is interposed between the first bus bar and the second bus bar, and includes cylinder portions. Each of the cylinder portions passes through corresponding one of third holes of the second bus bar, and allows corresponding one of branch portions of the first bus bar and corresponding one of terminals of the semiconductor modules to pass therethrough. An emitting angle of laser beam that bonds each of the terminals and the corresponding one of the branch portions is adjusted such that reflected beam of laser reaches the corresponding one of the cylinder portions. The cylinder portions are colored in a color comprising a wavelength of the laser.