Power Module Dual-Side Output Terminal Busbar Layout
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Solution Overview
Problem
Existing power modules for hybrid vehicles and electric cars face constraints in layout flexibility and design versatility due to complex wiring arrangements between output terminals and electric loads, leading to increased fabrication costs and reduced freedom in vehicle layout design.
Innovation Solution
A power module with multiple output terminals and a busbar arrangement within the casing allows for flexible electrical connections between terminals, enabling power to be supplied to electric loads from either side of the module without extending wiring or busbars outside the casing, thus enhancing layout freedom and design versatility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the output terminal position is fixed in conventional power modules, then the wiring arrangement becomes complicated and longer, but the layout flexibility in vehicle design is reduced
Solution Approach 1:
The power module is designed with multiple output terminals (first output terminal and second output terminal) that can serve different connection purposes. The busbar structure enables the module to be connected to electric loads from either side, making it universally adaptable to various vehicle layouts without requiring complicated individual wiring arrangements for each position.
Solution Approach 2:
The invention transitions from a single-sided output terminal configuration to a multi-dimensional arrangement by placing output terminals on both ends of the power module. The busbar extends across the upper region connecting terminals on opposite sides, enabling three-dimensional wiring flexibility that resolves the contradiction between wiring simplicity and layout adaptability.
2Manufacturing precision
If individual dedicated design is performed for each vehicle type, then the position relationship between output terminal and electric load is optimized, but fabrication cost increases due to inability to share components
Solution Approach 1:
The power module employs a universal design with multiple output terminals and a busbar configuration that can be adapted to different vehicle types without modification. The same module design can be used across multiple vehicle models, maintaining optimal position relationships through the flexible terminal arrangement rather than requiring dedicated designs for each vehicle type.
Solution Approach 2:
The busbar and output terminal configuration provides dynamic adaptability, allowing the same power module design to be optimally connected to electric loads regardless of their position in different vehicle layouts. This dynamic flexibility eliminates the need for static, vehicle-specific designs while maintaining manufacturing precision.
3Volume of moving object
If the power module size is reduced to meet vehicle layout constraints, then the degree of freedom for vehicle layout is increased, but the wiring complexity between output terminal and electric load increases
Solution Approach 1:
By utilizing both ends of the power module for output terminals and employing a busbar that spans the upper region, the invention effectively doubles the available connection directions. This dimensional expansion allows compact module sizing while maintaining simple wiring arrangements, as the electric load can be connected from the nearest terminal regardless of the module's position in the vehicle.
Solution Approach 2:
The multi-terminal configuration makes the compact power module universally applicable to various electric load positions. The same compact module design can serve different vehicle layouts without increasing wiring complexity, as the appropriate output terminal can be selected based on the electric load's position.
Data Source
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AI summary
Inverter circuits (151, 152) formed of a plurality of power semiconductor devices (210) are stored in a casing (280) of a power module (200). An output terminal (220) provided at one end side (281) of the casing (280) is connected to one inverter circuit (152). An output terminal (220) provided at the other end side (282) of the casing (280) is connected to another inverter circuit (152). An output terminal (230) configured to allow electric connection with an output terminal (220) located at the opposite side by a busbar (240) is further provided at each one end side (281) and the other end side (282). By disposing the busbar (240) appropriately, output from both inverter circuits (151, 152) can be provided from any of the one end side (281) and the other end side (282). An output terminal configuration can be realized that allows improvement in the degree of freedom for arrangement and versatility in circuit designing with respect to the position relationship with the electric load.