Power Module Conductive Wire Grouping for Air Bubble Escape
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Solution Overview
Problem
In power modules, the small gap between conductive wires leads to air bubbles in the sealing member, which lowers the insulating performance and reliability due to the introduction of air bubbles during the sealing process.
Innovation Solution
The power module design includes conductive wire groups with specific bonded portions and intermediate portions arranged in a way that maximizes the gap between them, allowing air bubbles to escape, and the use of a sealing member that seals these wire groups, ensuring improved reliability by preventing air bubbles from being trapped.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If the number of conductive wires is increased and the gap between adjacent conductive wires is made smaller to handle higher current without increasing module size, then the current handling capacity is improved, but air bubbles are more likely to be trapped in the sealing member below the conductive wires, lowering insulating performance and reliability
Solution Approach 1:
The conductive wires are divided into multiple conductive wire groups arranged in parallel. Each group contains multiple conductive wires that are bundled together, creating a segmented structure that allows air bubbles to escape through the gaps between groups while maintaining high current capacity through the increased total number of wires
Solution Approach 2:
The conductive wire groups are arranged asymmetrically with varying gaps between them. The gap between adjacent conductive wire groups is designed to be larger than the gap between individual wires within a group, creating asymmetric spacing that facilitates air bubble escape paths while maintaining compact overall structure
2Productivity
If the gap between adjacent conductive wires is made smaller to increase current density, then the current handling capacity per unit area is improved, but air bubbles introduced during sealing are more likely to remain trapped, lowering reliability
Solution Approach 1:
The problem is solved by transitioning from a two-dimensional arrangement of wires to a three-dimensional bundled structure. The conductive wire groups are arranged in parallel with their axes extending in the first direction, while the groups themselves are spaced in the second direction, creating multiple escape dimensions for air bubbles during the sealing process
3Power
If more conductive wires are packed into the same space to increase current capacity, then the power handling capability is improved, but the sealing process becomes more difficult without trapping air bubbles, reducing reliability
Solution Approach 1:
The conductive wires are segmented into distinct conductive wire groups that are easier to handle and seal as units. This segmentation allows the sealing process to accommodate the complex wire arrangement by treating each group as a manageable entity with controlled spacing for air bubble escape
Solution Approach 2:
Different regions of the conductive wire assembly have different gap characteristics. The gaps between conductive wire groups are locally optimized to be larger than gaps within groups, creating local quality variations that facilitate air bubble escape in critical sealing regions while maintaining compact wiring in other areas
Data Source
AI summary
A power module includes a plurality of conductive wire groups and a sealing member. The plurality of conductive wire groups each include a first bonded portion and a second bonded portion. A maximum gap between intermediate portions of a pair of conductive wire groups adjacent to each other is larger than a first gap between the first bonded portions of the pair of conductive wire groups adjacent to each other. The maximum gap between the intermediate portions of the pair of conductive wire groups adjacent to each other is larger than a second gap between the second bonded portions of the pair of conductive wire groups adjacent to each other. Therefore, the power module is improved in reliability.