Power Module Terminal Member With Intermediate Feet
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Solution Overview
Problem
Existing power modules in power electronic devices, such as motor drives and power converters in electric vehicles, face challenges in achieving reliable and efficient connections between substrates and external components, often requiring separate current-carrying terminal members and additional connection methods like wire bonds or metal clips.
Innovation Solution
A power module design featuring a terminal member with multiple feet, including intermediate and end feet, that provides both mechanical and electrical connections to external contacts, allowing for integrated substrate-to-substrate connections and eliminating the need for separate connection elements like wire bonds or clips, using methods such as welding, soldering, or gluing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate current-carrying terminal members and additional connection methods (wire bonds or metal clips) are used, then reliable connections between substrates and external components are achieved, but device complexity and manufacturing steps increase
Solution Approach 1:
The terminal member is designed to combine multiple functions: it serves as both the current-carrying terminal for external connections and as the substrate-to-substrate connection element. The integrated feet structure merges the previously separate wire bonds or metal clips into the terminal member itself, reducing device complexity while maintaining connection reliability.
2Reliability
If separate current-carrying terminal members and additional connection methods are used, then reliable connections are achieved, but manufacturing time and process steps increase
Solution Approach 1:
The terminal member integrates multiple connection functions into a single component that can be attached in one manufacturing step. The feet of the terminal member simultaneously connect to multiple substrates, eliminating the need for separate wire bonding or metal clip attachment processes, thereby improving manufacturing efficiency while ensuring reliable connections.
3Reliability
If multiple separate connection elements are used, then comprehensive electrical connections are achieved, but available space within the power module decreases
Solution Approach 1:
The terminal member consolidates multiple connection elements into a single integrated structure. The feet extend from the terminal to contact multiple substrates, providing comprehensive electrical connections while occupying less space than multiple separate wire bonds or metal clips would require, thus increasing the available internal space of the power module.
4Device complexity
If a single integrated terminal member is used, then device complexity and manufacturing steps are reduced, but connection reliability may be compromised
Solution Approach 1:
The terminal member is designed with differentiated feet having specific local properties optimized for their connection functions. Each foot can be tailored in terms of material, shape, and connection method to ensure optimal reliability for its specific connection point, while the overall structure remains integrated and simple.
Data Source
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AI summary
A power module (1) comprising several contact portions (6, 6', 7, 7', 37) and comprising a terminal member (2) with a terminal (3, 3') for electrically connecting one or more of the contact portions (6, 6', 7, 7', 37) to the outside and comprising at least one intermediate foot (4, 4', 28) contacting one of the contact portions (6, 6', 7, 7', 37), wherein the intermediate foot (4, 4', 28) is located between two sections (17, 18, 19) of the terminal member (2).