Power Module Signal Pins for Electric Axle Drive Inverters
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Solution Overview
Problem
Inverters in electric and hybrid vehicles experience signal transfer delays and increased leakage inductance due to long distances between semiconductor switches and drivers, leading to voltage fluctuations and reduced reliability.
Innovation Solution
The power module incorporates signal pins that extend vertically from the electrodes to the driver, reducing signal transfer resistance and leakage inductance, with design features such as S-shaped or wave-shaped intermediate segments, step-shaped foot segments, and insulating plastic connectors to enhance stability and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If long signal lines are used to connect electrodes to driver, then the distance between components is increased, but signal transfer delay and resistance increase
Solution Approach 1:
The signal pin extends vertically from the electrode upward to connect to the driver, changing the signal transmission path from a horizontal plane to a three-dimensional space. This vertical extension in the z-dimension significantly shortens the signal path length compared to horizontal routing, thereby reducing signal transfer delay and resistance while maintaining adequate component spacing.
Solution Approach 2:
The signal pin acts as an intermediary element that directly connects the electrode to the driver, eliminating the need for long horizontal signal lines. This intermediate vertical connection structure provides a low-resistance, low-inductance path for signal transfer, resolving the contradiction between component distance and signal transfer quality.
2Length of stationary object
If long signal lines are used to connect electrodes to driver, then component spacing is increased, but leakage inductance increases causing voltage fluctuations
Solution Approach 1:
By extending the signal pin vertically in the z-dimension, the patent creates a compact low-inductance loop area. This vertical orientation minimizes the parasitic inductance of the signal path, thereby reducing voltage fluctuations and electromagnetic interference while maintaining adequate spacing between power components.
Solution Approach 2:
The signal pin incorporates S-shaped or wave-shaped intermediate segments instead of straight rigid connections. These curved configurations reduce the inductance of the signal path by minimizing the enclosed loop area, thereby reducing voltage fluctuations and improving electrical performance while maintaining mechanical flexibility.
3Reliability
If vertical signal pins are used to reduce signal transfer resistance, then signal transfer reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The signal pin's geometry is optimized by introducing S-shaped or wave-shaped intermediate segments with specific curvature radii. These parameter changes allow the pin to achieve low inductance and high reliability while maintaining manufacturability through standard forming processes. The curved sections can be created using conventional wire forming or bending techniques during assembly.
Solution Approach 2:
The S-shaped and wave-shaped configurations of the signal pin intermediate segments reduce inductance while remaining compatible with standard manufacturing processes. These curved geometries can be produced through wire bending, forming, or molding operations that are already established in power module manufacturing, thereby limiting the increase in manufacturing complexity.
4Object-affected harmful factors
If signal pins with S-shaped segments are used to reduce inductance, then voltage fluctuations are reduced, but device complexity increases
Solution Approach 1:
The S-shaped and wave-shaped intermediate segments of the signal pin create compact low-inductance loops that effectively reduce voltage fluctuations. Despite the curved geometry, the signal pin remains a single integrated component that can be manufactured using standard wire forming or molding techniques, thereby limiting the increase in device complexity.
Solution Approach 2:
The signal pin with S-shaped or wave-shaped segments simultaneously achieves multiple functions: electrical connection, mechanical support, inductance reduction, and stress absorption. This multi-functionality is accomplished through a single component design that integrates all these features, thereby limiting the increase in overall device complexity while achieving superior electrical performance.
Data Source
AI summary
A power module for supplying electricity to an electric axle drive in an electric vehicle and/or hybrid vehicle may include numerous semiconductor switches for receiving an input current and generating an output current on the basis of the received input current by switching the semiconductor switches, where the semiconductor switches each have a positive current electrode, negative current electrode, and a control electrode, where numerous signal pins are each conductively connected to one of the electrodes, where at least one of the signal pins extends vertically, at least in part, between the electrode connected thereto and a driver.