Power Converter Transformer Layout for Vibration-Resistant Substrates
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric-power conversion apparatuses experience significant substrate bending during vibration, leading to stress on the substrate and potential breakage, especially when heavy components like transformers are mounted on the virtual center line.
Innovation Solution
The electric-power conversion apparatus is designed with connection portions arranged in linear alignment on the substrate, and mounting components like transformers are positioned off the virtual center line, ensuring equal distances to facing connection portions and a gravity center apart from the substrate's mounting surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a transformer with a high gravity center is mounted on the virtual center line of the substrate, then the substrate can be compactly designed, but substrate bending and vibration are significantly enlarged during operation
Solution Approach 1:
The transformer is deliberately positioned asymmetrically relative to the substrate's virtual center line. By placing the transformer at a location where the distance to one connection portion is greater than the distance to the opposing connection portion, the inertial forces generated during vibration are distributed more favorably, reducing substrate bending while maintaining compact dimensions.
2Adaptability or versatility
If heavy electronic components are mounted on the substrate, then the functional requirements are met, but the substrate bending becomes larger in proportion to the component weight
Solution Approach 1:
The connection portions are strategically positioned at locations on the substrate where structural support is most effective. By optimizing the local arrangement of connection portions and their distances from the transformer, the substrate's load-bearing capacity is enhanced at critical areas without requiring overall substrate enlargement or additional support structures.
3Area of stationary object
If the substrate is designed with supported portions only at outer-edge portions, then the substrate size is prevented from enlarging, but the central portion becomes vulnerable to bending under component weight
Solution Approach 1:
Instead of adding supported portions in the planar dimension (which would enlarge the substrate), the solution addresses the problem by optimizing the spatial arrangement of existing connection portions. The asymmetric positioning of the transformer relative to the connection portions creates a favorable force distribution that reduces bending moments without requiring additional dimensional space for support structures.
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 substrate bending during vibration, reducing stress on the substrate and preventing breakage, while also allowing for a more compact design and enhanced controllability of the switching device.
Implementation Method 1
When vibration in the surface direction of the substrate occurs in the substrate, inertial force generated in such a component whose gravity center is high with respect to the mounting surface makes the head-top portion of the component vibrate, as if a pendulum, on the mounting portion of the component, as a fulcrum
Implementation Method 2
inertial force generated in such a component whose gravity center is high with respect to the mounting surface makes the head-top portion of the component vibrate, as if a pendulum, on the mounting portion of the component, as a fulcrum
Implementation Method 3
Accordingly, in the substrate, force is exerted in the normal direction of the mounting surface thereof from the mounting portion of the component; thus, vibration that bends the substrate in the normal direction occurs
Implementation Method 4
when the transformer vibrates in the surface direction of the mounting surface of the substrate, substrate resonance in which the foregoing connection portions are nodes and a loop is made in the region sandwiched between the facing connection portions is liable to occur
Data Source
AI summary
There is provided an electric-power conversion apparatus that can suppress bending of a substrate at a time when vibration occurs in the substrate.The electric-power conversion apparatus includesa semiconductor module having a main body portion held to a case and two or more control terminals pulled out from the main body portion,a substrate on which respective connection portions to which the two or more control terminals are fixed in substantially linear alignment are arranged in such a way as to be substantially parallel to the alignment direction and in such a way as to face each other, anda transformer that is mounted at a position, on the substrate, avoiding a virtual center line, the respective distances from which to the facing connection portions are equal to each other, and whose gravity center is apart from a first mounting surface of the substrate in the normal direction.