Power Module Intermediate Electrode for Collector Sense Accuracy
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Solution Overview
Problem
Existing power modules with a 2in1 structure lack effective disclosure on collector sense connection, affecting detection accuracy in power conversion devices.
Innovation Solution
A power module design with a polygonal shape, featuring first and second active elements, conductors, and an intermediate electrode portion that connects the conductors, with the collector sense wiring positioned to improve detection accuracy by separating the sense connection from current concentration areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the collector sense wiring is connected close to the AC side terminal, then the connection is simplified, but the detection accuracy of collector sense voltage deteriorates due to self-inductance and current changes
Solution Approach 1:
The patent introduces an intermediate electrode portion as a mediator between the AC side terminal and the collector sense wiring connection point. This intermediate electrode serves as a buffer that separates the high-current AC terminal from the sensitive voltage detection path, allowing the collector sense wiring to connect at a distance from the AC terminal while maintaining electrical connection through the intermediate electrode. This resolves the contradiction by enabling both simplified connection (through the intermediate electrode) and improved detection accuracy (by distancing from current concentration areas).
2Measurement precision
If the collector sense connection point is positioned far from the AC side terminal, then detection accuracy improves, but the wiring length increases and complexity increases
Solution Approach 1:
The patent utilizes the vertical dimension by positioning the intermediate electrode portion between the AC side terminal and the collector sense wiring connection point in the thickness direction of the module. This three-dimensional arrangement allows the collector sense wiring to connect at an optimal distance from the AC terminal for accurate voltage detection, while the intermediate electrode provides a direct electrical pathway that minimizes the effective electrical path length. This spatial arrangement resolves the contradiction between detection accuracy and wiring length.
3Power
If the intermediate electrode portion is positioned close to the AC side terminal, then current conduction is optimized, but the collector sense detection accuracy deteriorates due to self-inductance effects
Solution Approach 1:
The patent segments the electrical connection path into two distinct functional portions: the intermediate electrode portion positioned close to the AC side terminal for optimized current conduction, and the collector sense wiring connection point positioned far from the AC terminal for accurate voltage detection. This segmentation allows each portion to be optimized for its specific function - the intermediate electrode handles high-current conduction while the distant sense connection handles precise voltage measurement, resolving the contradiction between current conduction efficiency and detection accuracy.
Data Source
AI summary
Detection accuracy of a collector sense in detecting a voltage is improved.A power module 300 has a first conductor 410 and a second conductor 411 to which a plurality of active elements 317 and 315 configuring upper and lower arm circuits are connected. In addition, the power module 300 has an AC side terminal 320B protruding from one side 301a, a positive electrode side terminal 315B and a negative electrode side terminal 319B which protrude from the other side 301b, an intermediate electrode portion 414 that connects the first conductor 410 and the second conductor 411 to each other, and a collector sense wiring 452a in which a collector electrode of an active element 157 and the first conductor 410 are connected to each other via a sense connection portion 415. The intermediate electrode portion 414 is disposed close to the active element 157 which is closest to the AC side terminal 320B, and the sense connection portion 415 is disposed close to the active element 157 which is farthest from the AC side terminal 320B.