Power Conversion Circuit Module Layout to Prevent Soldering Misalignment

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Solution Overview

Problem

Existing power conversion circuit modules face issues with deviation of electronic components from their desired orientation or position due to heating during soldering processes.

Innovation Solution

The power conversion circuit module design includes a circuit board with conductors that have support portions and specific electrode arrangements, ensuring that electronic components like coils and capacitors remain aligned and stable during soldering by utilizing conductors with plate-shaped portions and support structures that prevent warping and sliding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional soldering processes are used to attach electronic components, then electrical connectivity is achieved, but deviation of components from desired orientation or position occurs due to heating

Engineering Contradiction:

Improveelectrical connectivityVSAvoidcomponent position and orientation

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent applies preliminary action by pre-positioning the coil and capacitor on the conductor before the soldering process. The conductor is designed with specific geometric features (plate-shaped portion, support portions, recessed portion) that physically constrain the components in their desired positions and orientations before heating occurs. This preliminary structural arrangement prevents deviation during the subsequent soldering heating process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conductor acts as an intermediary between the circuit board and the electronic components. It provides a stable mounting structure with support portions that hold the coil and capacitor in place, isolating them from the direct thermal and mechanical effects of the soldering process. The conductor's rigid structure mediates the connection while maintaining component positioning accuracy.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If heating is applied during soldering to achieve electrical connectivity, then components are joined, but warping and sliding of components occur

Engineering Contradiction:

Improveelectrical connectivityVSAvoidcomponent alignment and position

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent applies preliminary anti-action by designing the conductor with built-in counteracting features that oppose the warping and sliding forces generated during heating. The support portions and recessed portion create mechanical constraints that counterbalance the thermal expansion and gravitational forces acting on the components during the soldering process, preventing deviation from desired positions.

Inventive Principle:

Principle #9Preliminary anti-action

Solution Approach 2:

The conductor's geometric parameters (thickness, support portion dimensions, recessed portion depth) are specifically designed to change the mechanical stiffness and thermal expansion characteristics of the assembly. These parameter changes enable the conductor to resist warping and sliding during heating while maintaining electrical connectivity.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If conventional mounting structures are used, then assembly is simple, but inductance value degradation and capacitor breakdown risks increase

Engineering Contradiction:

Improveassembly simplicityVSAvoidinductance stability and capacitor integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The conductor is segmented into distinct functional portions: a plate-shaped portion for mounting, support portions for positioning, and a recessed portion for securing the capacitor. This segmentation allows each portion to perform its specific function (mechanical support, positioning, or securing) while maintaining overall structural integrity and simplicity of manufacture.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS20260045890A1Power conversion circuit module and power conversion system

Publication Date: 2026.02.12 MURATA MFG CO LTD

AI summary

A power conversion circuit module includes a coil including first and second coil electrodes, and one or more capacitors each including first and second capacitor electrodes. A mass of the coil is larger than a mass of each of the one or more capacitors. First, second, and third conductors each include a second upper surface and a second lower surface arranged in an up-down direction. Each of the first and second coil electrodes is provided on the second upper surface of the first conductor. The second coil electrode is provided on the second upper surface of the second conductor. The first capacitor electrode is provided on the second upper surface of the third conductor.