Power Converter Laminate Structure for Vibration Resistance
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Solution Overview
Problem
Existing capacitor modules for vehicle-mounted electrical-mechanical systems are large, prone to stress rupture due to severe temperature and vibration, and do not effectively reduce parasitic inductance, leading to increased switching losses and heat generation in power converters.
Innovation Solution
A capacitor module design featuring a laminate structure with wide conductors joined in a layered form, including a bent portion to moderate stresses and reduce inductance, and a resin-molded construction for enhanced thermal conductivity and connection efficiency, allowing for a low-inductance, space-saving configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If capacitors are connected in proximity relation to reduce inductance, then parasitic inductance is reduced, but stresses are concentrated in connecting portions causing rupture in severe temperature and vibration environments
Solution Approach 1:
A stress-absorbing member is introduced as an intermediary component between the capacitor and the circuit board. This member absorbs mechanical stresses caused by temperature changes and vibrations, preventing stress concentration at the connecting portions while maintaining the low-inductance proximity connection. The stress-absorbing member acts as a buffer that decouples the mechanical stress from the electrical connection.
2Reliability
If a third connecting member is used to moderate stresses, then reliability is improved, but inductance in the connecting portion increases
Solution Approach 1:
The stress-absorbing member is designed as a flexible component with a specific structure that allows it to moderate stresses while maintaining low inductance. The flexible nature of this component enables it to absorb mechanical stresses without creating long rigid connecting paths that would increase inductance. The thin-film or flexible structure minimizes the electrical path length while providing mechanical compliance.
3Volume of moving object
If capacitors are arranged in a compact configuration, then space is saved, but thermal management becomes difficult due to heat generation from ripple current
Solution Approach 1:
The capacitor is designed with a case that copies or replicates the heat dissipation function of a heat sink. The case structure is designed to efficiently conduct heat away from the capacitor interior, where ripple current generates heat, and dissipate it to the surrounding environment. This integrated heat dissipation design allows compact arrangement while maintaining effective thermal management.
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 achieves reduced parasitic inductance, lower switching losses, and improved thermal management, enabling a smaller, more efficient power converter with enhanced reliability and heat dissipation.
Implementation Method 1
the capacitor is required to have a shape ensuring high thermal conduction and good thermal contact for heat radiation
Data Source
AI summary
A power converter in which the structure of a connecting portion is highly resistant against vibration and has a low inductance. The power converter includes a plurality of capacitors and a laminate made up of a first wide conductor and a second wide conductor joined in a layered form with an insulation sheet interposed between the first and second wide conductors. The laminate comprises a first flat portion including the plurality of capacitors which are supported thereon and electrically connected thereto, a second flat portion continuously extending from the first flat portion while being bent, and connecting portions formed at ends of the first flat portion and the second flat portion and electrically connected to the exterior.