Power Converter Vibration Resistance via Planar Module Overhang Reduction
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Solution Overview
Problem
Existing power converters face issues with low vibration resistance and increased volume due to signal pin interference and brittleness, as well as low accuracy in current sensing caused by long wiring picking up noise.
Innovation Solution
A power converter design featuring planar semiconductor modules with resin sealing, a cooler with refrigerant tube parts, and a cover that supports the resin sealing and cooler in proximity, with conductive members and signal terminals protruding away from the cover to reduce overhang, along with a current sensor and control board connected by a shortened harness to minimize noise.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If signal pins extend from one side of the power module and bus bars extend from the other side, then connections can be established, but the overhang amount increases and vibration resistance decreases
Solution Approach 1:
The patent transitions from a planar arrangement where signal pins and bus bars extend in opposite directions (increasing overhang) to a three-dimensional arrangement where both extend from the same side of the power module. This dimensional change allows both connection types to be compactly arranged near the module edge, reducing the overhang amount and improving vibration resistance.
2Measurement precision
If signal pins and bus bars are arranged with maximum separation, then interference is reduced, but the wiring distance increases and noise pickup increases
Solution Approach 1:
The patent merges the exit positions of signal pins and bus bars to the same side of the power module, allowing the current sensor and control board to be positioned nearby. This consolidation reduces the wiring distance significantly while maintaining proper electrical isolation through the resin sealing part, thereby reducing noise pickup and improving measurement precision.
3Reliability
If power modules are held in a traditional configuration, then assembly is straightforward, but the modules may deviate from normal positions and break due to vibration
Solution Approach 1:
The holding structure is segmented into multiple support portions that independently hold different components (power modules, current sensors, control board) at optimized positions. This segmentation allows each component to be securely positioned with minimal overhang, improving overall stability and vibration resistance while maintaining assembly simplicity through modular support elements.
Data Source
AI summary
A power converter (1) includes: planar semiconductor modules (10) each having a resin sealing part (16) in which a semiconductor element (11), conductive members (12, 13, and 14), and a signal terminal (15) are sealed with a resin; a cooler (20) that holds the plurality of semiconductor modules (10) in a laminated manner; and a cover (30) that covers the semiconductor modules and the cooler, wherein at least a part of the resin sealing part (16) and the cooler (20) are supported by support media (41 and 42) that extend from the cover (30) so that facing parts of the resin sealing part and the cooler with respect to the cover (30) is positioned in proximity to the cover, and the conductive members and the signal terminal protrude from the resin sealing part in a direction away from the cover.