Power Converter Sub-Module Layout for Substrate Thermal Isolation
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Solution Overview
Problem
The substrate in a power conversion device is heated by the heat sources such as IGBTs and laminated bus bars when they are disposed in the same space, leading to thermal issues.
Innovation Solution
The power conversion device includes a housing frame and separation frames that separate the space for the drive circuits and substrates from the space for IGBTs and laminated bus bars, with cooling fins and openings for airflow to manage heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the substrate and heat sources (IGBT and laminated bus bar) are disposed in the same space, then the device structure is simplified, but the substrate is heated by the heat source
Solution Approach 1:
The housing frame is divided into a first housing portion and a second housing portion that are separated by a predetermined distance, creating distinct spatial zones. The substrate is mounted on the first housing portion while heat sources are mounted on the second housing portion, physically segmenting the device to prevent thermal coupling between components.
2Temperature
If the substrate is isolated from heat sources, then substrate heating is suppressed, but the device structure becomes more complex
Solution Approach 1:
The housing frame serves multiple functions simultaneously: it provides structural support for mounting the substrate and heat sources, creates thermal isolation through spatial separation, and maintains electrical insulation. This multi-functionality achieves thermal management without adding separate dedicated cooling structures.
3Loss of energy
If cooling structures are added to the device, then heat dissipation is improved, but the device complexity increases
Solution Approach 1:
The spatial separation of heat-generating components from heat-sensitive components enables passive thermal management. The device structure itself, through the separated housing portions, provides the cooling function without requiring active cooling systems, fans, or complex thermal management components.
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 effectively suppresses the heating of the substrates by isolating them from direct heat sources, improving thermal management and device performance.
Implementation Method 1
a separation frame for separating a space in which the drive circuit and the substrate are disposed from a space in which the IGBT and the laminated bus bar are disposed
Implementation Method 2
the substrate and a heat source such as the IGBT and the laminated bus bar are disposed in the same space, the substrate is heated by the heat source
Data Source
AI summary
A sub-module of a power conversion device includes: an IGBT, a drive circuit that drives the IGBT, a laminated bus bar on which the IGBT is mounted; a substrate on which the drive circuit is mounted; a housing frame for accommodating the IGBT, the drive circuit, the laminated bus bar, and the substrate; and a separation frame for separating a space in which the drive circuit and the substrate are disposed from a space in which the IGBT and the laminated bus bar are disposed.