Power Converter Segmented Cover for Cooling and Protection

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Solution Overview

Problem

Existing power converters face challenges in efficiently cooling and protecting circuit elements from environmental factors like water, dust, and vibrations, which limits their versatility and reliability in various industrial applications.

Innovation Solution

The power converter design includes a housing with distinct spaces for circuit substrates and cooling fluid passages, where circuit elements protrude into a secondary space covered by a segmented cover with larger and smaller regions, utilizing insulating materials and vibration isolators to enhance cooling and protection while minimizing the device's outer shape.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If circuit elements are exposed to the external environment for easier access and maintenance, then ease of operation is improved, but protection from environmental factors (water, dust, vibrations) deteriorates

Engineering Contradiction:

Improveaccess to circuit elementsVSAvoidprotection from environmental factors

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The cover is divided into a first cover portion and a second cover portion that can be separated from each other. The first cover portion covers the circuit elements when viewed from the direction of protrusion, while the second cover portion is separable to provide access. This segmentation allows the cover to protect circuit elements during operation while enabling easy access during maintenance without compromising protection.

Inventive Principle:

Principle #1Segmentation

2Ease of manufacture

If the cover structure is simplified to reduce manufacturing complexity, then ease of manufacture is improved, but protection effectiveness and adaptability deteriorate

Engineering Contradiction:

Improvecover structure complexityVSAvoidprotection effectiveness

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cover structure provides different levels of protection and functionality in different regions. The first cover portion provides continuous protection, while the second cover portion provides selective access. This local differentiation optimizes both protection effectiveness and ease of manufacture by applying complexity only where necessary.

Inventive Principle:

Principle #3Local quality

3Reliability

If the power converter design is optimized for specific industrial environments, then reliability in those environments is improved, but adaptability to wider range of environments deteriorates

Engineering Contradiction:

Improvereliability in specific environmentsVSAvoidadaptability to different environments

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The cover structure serves multiple functions: it protects circuit elements from environmental factors, provides selective access for maintenance, and can be configured in different ways depending on installation requirements. The separable second cover portion and the first cover portion work together to provide universal protection and access capabilities that adapt to various industrial environments while maintaining reliable protection.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 configuration improves heat resistivity, protects circuit elements from environmental factors, and increases vibration resistance, allowing the power converter to be installed in a wider range of environments with enhanced reliability and cooling efficiency.

Implementation Method 1

a passage for a cooling fluid is disposed

Methodology Applied

Scientific EffectConvection: Convection

Implementation Method 2

improves heat resistivity

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS10039215B2Power converter

Publication Date: 2018.07.31 YASKAWA DENKI KK

AI summary

A power converter includes a housing, a circuit element, and a cover. The housing includes a first space and a second space. In the first space, a circuit substrate is disposed. In the second space, a passage for a cooling fluid is disposed. The circuit element is disposed on the circuit substrate in the first space and protrudes into the second space. The cover covers at least a portion of the circuit element and includes a first portion and a second portion. The first portion protrudes from near the circuit substrate into the second space, and defines a first region that has a first area. The second portion protrudes from the first portion, and defines a second region that has a second area. The first area is larger than the second area as viewed from a direction in which the circuit element protrudes.