Power Control Unit Bus Bar Layout for Smaller Module Footprint
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Solution Overview
Problem
Existing power control units for electric vehicles are large in plan view due to the need for wide disposition spaces for bus bars and power devices, which increases the overall size of the unit.
Innovation Solution
The power control unit configuration includes power devices arranged in a row with plate-shaped bus bars erected perpendicular to the heat dissipation member, allowing input and output bus bars to be positioned orthogonally, reducing the installation space required for the bus bars and power devices, and utilizing insulating resin members to manage heat and reduce the unit's size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a plate-shaped bus bar is disposed with front and back surfaces facing vertical direction and power devices are disposed on both sides, then the bus bar can be connected to power devices, but the disposition space becomes wide and the power control unit size increases
Solution Approach 1:
The bus bar is changed from a flat horizontal disposition to an erected vertical disposition, utilizing the height dimension to reduce plan view area. The bus bar stands upright with its plate width direction aligned with the normal line direction of the heat dissipation member, allowing power devices to be arranged more compactly in the plan view while maintaining electrical connection functionality.
2Reliability
If bus bars are disposed horizontally with power devices on both sides, then electrical connection is achieved, but the plan view area increases
Solution Approach 1:
The bus bar configuration transitions from horizontal to vertical orientation, moving the electrical connection structure into the height dimension. This allows the same electrical connection function to be achieved with reduced plan view footprint, as the bus bar now extends vertically rather than horizontally across the power devices.
3Area of stationary object
If the power control unit size is reduced, then the plan view area decreases, but the disposition space for bus bars and power devices becomes insufficient
Solution Approach 1:
By erecting the bus bar vertically and aligning its plate width direction with the normal line direction of the heat dissipation member, the design utilizes the vertical dimension to accommodate bus bar geometry. This enables compact plan view arrangement of power devices around the vertically-oriented bus bar, maintaining adequate disposition space for manufacturing while minimizing the overall plan view area of the power control unit.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration minimizes the installation space for bus bars and power devices, resulting in a smaller power control unit size while effectively managing heat dissipation, thereby reducing the overall size of the power module and control unit in plan view.
Implementation Method 1
a plate-shaped bus bar which has one end connected to the power device... with an insulating resin member interposed therebetween
Implementation Method 2
a heat dissipation member disposed to face the power device with an insulating resin member interposed therebetween
Data Source
AI summary
A power control unit includes a plurality of power devices, a heat dissipation member disposed to face the power device with an insulating resin member interposed therebetween, and a plurality of plate-shaped bus bars each of which has one end connected to the power device, in which at least one of the plurality of bus bars is erected so that a direction along a plate width is aligned with a direction along a normal line of a surface of the heat dissipation member facing the power device, the power devices are arranged in a row along one direction in a straight line, an input bus bar is disposed on one side of the power device in a direction orthogonal to an arrangement direction of the power device, and an output bus bar is disposed on the other side of the power device in the orthogonal direction.