Power Converter Lead Bending for Bus Bar Bonding Reliability
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Solution Overview
Problem
Conventional power converters for electric and hybrid vehicles face challenges in reliable bonding between bus bars and connection leads due to dimensional variations, leading to misalignment and inconsistent electrical connections.
Innovation Solution
The power converter design incorporates a lead with a bending part inclined at an acute angle to the bus bar, allowing for precise bonding via solder, which adjusts for misalignment and ensures reliable electrical connections by forming fillets at acute wetting angles, facilitating easy inspection and improved workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional vertical bonding of bus bar and lead is used, then manufacturing is simple, but bonding reliability is poor due to misalignment from dimensional variations
Solution Approach 1:
The lead is designed with a curved arc shape instead of a straight configuration. This curvature allows the lead to naturally accommodate dimensional variations and misalignment between the bus bar and semiconductor device, improving bonding reliability while maintaining manufacturing simplicity
Solution Approach 2:
The invention transitions from a two-dimensional planar lead layout to a three-dimensional curved configuration. The lead extends in multiple directions (first direction toward bus bar, second direction toward semiconductor device, third direction forming the arc), creating spatial flexibility that absorbs dimensional variations without compromising bonding reliability
2Difficulty of detecting and measuring
If lead is bonded directly to bus bar without spacing, then connection is compact, but inspection and quality control become difficult
Solution Approach 1:
The lead is pre-formed with a specific arc shape and spacing distance before the bonding process. This preliminary configuration ensures that the lead maintains an optimal distance from the bus bar, creating sufficient space for inspection while ensuring proper bonding conditions are met
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 enhances the reliability of power converter bonding by accommodating dimensional variations, ensuring consistent connections and improving inspection and manufacturing efficiency.
Implementation Method 1
The vertical wall of the bus bar and the bending part are bonded to each other via the solder
Data Source
AI summary
A power converter includes a bus bar, a semiconductor device, a lead, and solder. The bus bar has a vertical wall. The semiconductor device includes an electrode. The lead has one end connected to the bus bar and another end connected to the semiconductor device to supply power from the bus bar to the electrode of the semiconductor device via the lead. The one end of the lead includes a bending part which is spaced away from the bus bar by a predetermined distance and which is inclined in a vertical downward direction. The vertical wall of the bus bar and the bending part are bonded to each other via the solder. The vertical wall extends in a substantially vertical direction to face the bending part.