3D Power Module Bus Layout for Lower Parasitic Inductance
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Solution Overview
Problem
Existing power electronic modules suffer from parasitic inductance issues, which induce overvoltage in switching devices during operation, limiting their nominal operating voltage and increasing switching losses and electromagnetic noise.
Innovation Solution
The power electronic module is designed with a three-dimensional configuration of positive and negative drivers and their connections to switching devices, such that the magnetic fields generated by current circulation in consecutive switching cells are oppositely oriented, partially compensating parasitic inductances and reducing overvoltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If conventional three-dimensional arrangement of DC bus with positive and negative conductors placed opposite each other is used, then spatial concentration of parasitic inductance is achieved, but overvoltage at switching devices increases and nominal operating voltage is limited
Solution Approach 1:
The patent applies asymmetry by arranging the positive and negative conductors in a non-opposite configuration. Specifically, the conductors are positioned such that switching cells adjacent to the same conductor experience different magnetic field conditions, creating an asymmetric layout that reduces parasitic inductance concentration while maintaining electrical performance.
Solution Approach 2:
The patent transitions from a conventional two-dimensional planar arrangement to a three-dimensional spatial configuration. The conductors are arranged in multiple layers and positions (e.g., some conductors above the substrate, others below, at different heights), utilizing the third dimension to optimize magnetic field distribution and reduce parasitic inductance effects on switching devices.
2Productivity
If parasitic inductance is reduced through conductor arrangement, then overvoltage is minimized and switching frequency can be increased, but electromagnetic noise may increase
Solution Approach 1:
The patent converts the potentially harmful effect of current loops into a beneficial arrangement by deliberately designing the conductor paths and switching cell layouts to create opposing magnetic fields. The current loops that would normally generate parasitic inductance are arranged to produce canceling magnetic effects, transforming the harmful inductance into a useful flux cancellation mechanism.
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 reduces parasitic inductances, minimizing overvoltage and allowing for switching devices with nominal operating voltage closer to the rated voltage, thereby increasing switching frequency, reducing losses, and minimizing electromagnetic noise.
Implementation Method 1
a magnetic field generated by a flow of current in the positive and negative conductors and one of the two switching cells has a direction opposite to a magnetic field generated by a flow of current in the positive and negative conductors and the other of the two switching cells
Implementation Method 2
parasitic inductance that opposes the variation of current. This parasitic inductance can induce an overvoltage at the switching devices when they open and close
Data Source
Figure 1~2
Figure 3
Figure 4A~4C
AI summary
This disclosure relates to a power electronic module (1) comprising at least two switching cells (2a,2b) each extending in parallel between a positive conductor (3) and a negative conductor (4) of a DC bus, each of the switching cells (2a,2b) comprising a high switching device (21a,21b) and a low switching device (22a,22b), in which the positive conductor (3), the negative conductor (4) and their connection respectively to the high (21a,21b) and low (22a,22b) switching devices are three-dimensionally shaped such that, for two consecutive switching cells (2a,2b), a magnetic field generated by a current flow in the positive and negative conductors and one of the two switching cells (2a) has a direction opposite to a magnetic field generated by a current flow in the positive and negative conductors and the other of the two switching cells (2b).