Power Conversion Device Substrate Connector Design

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Solution Overview

Problem

The existing power conversion devices have a reduced region for mounting electronic components on the first printed wiring board due to the screws used to fasten the first printed wiring board to the power module.

Innovation Solution

The power conversion device includes a power module installing member, a power module, a bus bar assembly, a first substrate with a first printed wiring board, and a second substrate. The first substrate includes connectors on the printed wiring board, and the second substrate is fixed to the bus bar assembly, allowing the first substrate to be fixed without screws, thereby enlarging the mountable region for electronic components.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the first printed wiring board is fastened to the power module by a plurality of screws, then the connection between the printed wiring board and power module is secure, but the region in which electronic components can be mounted on the first printed wiring board is reduced

Engineering Contradiction:

Improveconnection strengthVSAvoidmountable region area

Core Design Contradiction:

StrengthVSArea of stationary object

Solution Approach 1:

The connection function is segmented between the bus bar assembly (which provides mechanical support and connection points) and the first printed wiring board (which provides electrical connections and component mounting). By separating these functions, the PWB can be connected without screws while maintaining connection strength and preserving mounting area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The bus bar assembly acts as an intermediary between the power module and the first printed wiring board. Instead of directly screwing the PWB to the power module, the bus bar assembly mediates the connection, allowing the PWB to be mounted without screws while maintaining secure electrical and mechanical connections.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If screws are used to fasten the first printed wiring board to the power module, then reliable electrical connection is achieved, but the assembly process becomes more complex and time-consuming

Engineering Contradiction:

Improveelectrical connection reliabilityVSAvoidassembly process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The screws and screw-fastening mechanism are extracted from the assembly process. The connection is achieved through the bus bar assembly structure and connector interfaces, eliminating the need for screws and simplifying the assembly process while maintaining electrical connection reliability.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The mechanical support, electrical connection, and structural alignment functions are merged into the bus bar assembly. This integration eliminates the need for separate screw fastening operations, reducing assembly complexity while ensuring reliable electrical connections through the integrated structure.

Inventive Principle:

Principle #5Merging (Combining)

3Stability of the object's composition

If screws are arranged on the first printed wiring board for fastening, then secure mounting is achieved, but the number of assembly steps increases

Engineering Contradiction:

Improvemounting stabilityVSAvoidassembly time

Core Design Contradiction:

Stability of the object's compositionVSLoss of time

Solution Approach 1:

The bus bar assembly is pre-configured with connection points and structural features that enable direct mounting of the first printed wiring board without screws. This preliminary preparation of the mounting structure eliminates the need for screw fastening steps, reducing assembly time while maintaining mounting stability.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The mechanical screw fastening system is replaced with an alternative mounting mechanism based on the bus bar assembly structure, which provides stable mounting through structural integration rather than threaded fasteners. This substitution eliminates the time-consuming screw fastening process while maintaining mounting stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12302500B2Power conversion device including substrates with connectors

Publication Date: 2025.05.13 MITSUBISHI ELECTRIC CORP

AI summary

Provided is a power conversion device with which a region in which an electronic component is mountable in a first printed wiring board of a first substrate can be enlarged. The power conversion device includes a power module installing member, a power module, a bus bar assembly, a first substrate provided on the bus bar assembly, and a second substrate provided on the bus bar assembly. The first substrate includes a first printed wiring board, and a signal terminal connector and a first board-to-board connection connector which are each provided on the first printed wiring board. The second substrate includes a second printed wiring board and a second board-to-board connection connector provided on the second printed wiring board. The signal terminal connector is connected to a signal terminal of the power module. The first board-to-board connection connector and the second board-to-board connection connector are connected to each other.