Power Converter Partition Shields Current Sensor

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Solution Overview

Problem

In fuel cell units, the downsizing of power converters leads to increased heat and magnetic flux influences on current sensors, compromising their heat resistance and measurement accuracy due to proximity to reactors and leakage fluxes.

Innovation Solution

A power converter design incorporating a metal partition with magnetic shielding effects to separate the reactor from the current sensor, along with a long bus bar length and strategic bus bar routing to reduce heat and magnetic flux impacts, while using a water-cooling system to manage temperatures.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the power converter is downsized to reduce spatial occupation, then the mounting space requirement is reduced, but the heat and magnetic flux influence on current sensors increases

Engineering Contradiction:

Improvepower converter sizeVSAvoidheat and magnetic flux influence on current sensor

Core Design Contradiction:

Volume of moving objectVSObject-affected harmful factors

Solution Approach 1:

The power converter is divided into separate functional spaces: a reactor space for housing the reactor and a sensor space for housing the current sensor. A partition wall physically segments these spaces, isolating the current sensor from the harmful heat and magnetic flux generated by the reactor while maintaining the compact overall size of the power converter.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

A partition wall made of heat-resistant material with magnetic shielding properties is introduced as an intermediary structure between the reactor and the current sensor. This partition wall blocks and shields the harmful thermal and magnetic influences from reaching the current sensor, allowing the power converter to be downsized without compromising sensor performance.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Volume of moving object

If the distance between reactor and current sensor is reduced due to downsizing, then the spatial occupation is reduced, but the measuring accuracy of current sensor deteriorates

Engineering Contradiction:

Improvepower converter sizeVSAvoidcurrent sensor measurement accuracy

Core Design Contradiction:

Volume of moving objectVSMeasurement precision

Solution Approach 1:

The internal space is segmented into distinct reactor and sensor zones separated by a partition wall. This segmentation allows the current sensor to be positioned in close proximity to the reactor for compact design while the partition wall maintains measurement accuracy by blocking magnetic flux leakage from affecting the sensor.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The partition wall acts as a magnetic shielding intermediary that allows physical proximity between reactor and sensor for downsizing purposes while preventing magnetic flux from degrading the current measurement accuracy. The heat-resistant material also maintains thermal isolation.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Volume of moving object

If the bus bar length is shortened to reduce spatial occupation, then the power converter size is reduced, but the heat transfer from reactor to current sensor increases

Engineering Contradiction:

Improvepower converter sizeVSAvoidheat transfer to current sensor

Core Design Contradiction:

Volume of moving objectVSTemperature

Solution Approach 1:

The partition wall creates separate thermal zones, allowing the bus bar to be shortened for compact design while the partition prevents heat generated by the reactor from transferring to the current sensor through the bus bar or surrounding air.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The heat-resistant partition wall serves as a thermal intermediary that blocks heat transfer pathways. This allows the bus bar length to be reduced for downsizing while the partition maintains thermal isolation between the hot reactor region and the sensitive sensor region.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 the influence of radiant heat and leakage fluxes on current sensors, maintaining their heat resistance and improving measurement accuracy by isolating them from reactor heat and magnetic interference.

Implementation Method 1

The partition is made of metal having a magnetic shielding effect, the partition being configured to separate the reactor from the current sensor

Methodology Applied

Scientific EffectMagnetic shielding: Magnetic Field

Implementation Method 2

the partition reduces the influence of radiant heat from the reactor on the current sensor

Methodology Applied

Scientific EffectThermal radiation blocking: Thermal Radiation

Data Source

PatentUS11469680B2Power converter

Publication Date: 2022.10.11 DENSO CORP

AI summary

A current sensor is provided on a bus bar via which a reactor is connected to a power module. The reactor is separated from the current sensor by a partition made of metal having a magnetic shielding effect. An output terminal of the reactor is provided on either one of a surface of the reactor on a first side and a surface of the reactor on a second side, the first side being farther from a mounting surface of a power converter across a plane passing through the center of the reactor, the second side being closer to the mounting surface from the plane.