Power Module Charge-Reversal Path Design
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Solution Overview
Problem
Existing power modules in medium or high voltage converters face issues with parasitic capacitances leading to electromagnetic interference (EMI) and potential short circuits due to undefined current discharge paths, which complicates testing and increases production costs.
Innovation Solution
A power module design that includes an electrically conductive cooling device connected to a protective housing with a predefinable insertion opening for a connecting element, forming a defined charge-reversal path between the cooling device and busbars, thereby reducing parasitic capacitances and enhancing electromagnetic compatibility (EMC).
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conductor bars are used for contacting power modules, then current conduction is improved, but parasitic capacitances are generated causing electromagnetic interference
Solution Approach 1:
A connecting element is introduced as an intermediary component between the conductor bar and the cooling device. This connecting element provides a defined charge-reversal path that mediates the parasitic capacitance effect, allowing charge to reverse through a controlled path rather than creating unwanted electromagnetic interference. The connecting element thus serves as a mediator that maintains the beneficial current conduction while eliminating the harmful EMI effects.
2Reliability
If separate testing of individual components is performed, then component functionality is verified, but assembly damage and undefined current discharge paths may occur
Solution Approach 1:
The connecting element is designed to be inserted through an insertion opening in the protective housing before final assembly completion. This preliminary action allows the defined charge-reversal path to be established early in the assembly process, enabling subsequent testing to be performed on the complete module structure without risking undefined current discharge paths. The preliminary placement of the connecting element prevents assembly damage while maintaining component functionality verification.
3Reliability
If testing is performed on completed power modules, then overall module functionality is verified, but manual effort and production costs increase
Solution Approach 1:
The defined charge-reversal path is established through the connecting element before final module completion, enabling automated testing procedures to be implemented on the complete module structure. This preliminary setup eliminates the need for manual testing efforts while ensuring overall module functionality is verified. The connecting element's early placement facilitates efficient production workflows without compromising reliability verification.
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 design effectively prevents parasitic discharge currents from reaching undesired locations, reduces material degradation, and simplifies testing and production, improving safety and quality while minimizing costs.
Implementation Method 1
The abruptly changing electric potential of current-carrying conductor bars can cause charge-reversal processes of electrical charge between the conductor bars and other, especially flat, components of the power module, which is referred to as parasitic capacitances.
Implementation Method 2
The cooling device is configured to be electrically conductive and connected to a protective housing shielding at least the power semiconductor module from the environment
Data Source
AI summary
The invention relates to a method for producing a power module (1) and a power module (1), in particular for a medium or high voltage converter (2), comprising at least one power semiconductor module (3), at least one energy storage module (5), at least one cooling device (7), at least two busbars (10), wherein the cooling device (7) is configured to be electrically conductive and is connected to a protective housing (19) shielding at least the power semiconductor module (3) from the environment, which protective housing (19) has at least one insertion opening (20) for inserting and fastening a connecting element (15), and an electrically conductive connecting element (15) is arranged at a predefinable connection position (16) between at least the cooling device (7) and one of the busbars (10) for forming a defined charge-reversal path (17).