Pressure Contact Three-Phase Converter Module Design
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Solution Overview
Problem
Existing three-phase power converter modules face challenges in optimizing the arrangement and contact efficiency of auxiliary and load connection elements, which affects thermal and electrical performance and longevity.
Innovation Solution
A pressure-contact three-phase power converter module design featuring substrates with insulating bodies and conductor tracks, load connection elements as shaped metal bodies with contact feet, and auxiliary connection elements as contact springs, arranged to ensure even pressure distribution and contact, enhancing thermal and electrical connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If auxiliary connection elements are arranged independently of load connection elements, then routing flexibility is improved, but space utilization and contact efficiency deteriorate
Solution Approach 1:
The patent combines auxiliary connection elements and load connection elements into a single integrated connection element. The auxiliary contact and load contact are formed as separate contact regions on the same connection element, allowing both functions to be realized within the same structural footprint. This merging approach improves space utilization while maintaining the flexibility to route different potentials independently through the respective contact regions.
2Temperature
If pressure is applied to ensure thermal contact, then thermal dissipation is improved, but contact uniformity and electrical performance may deteriorate
Solution Approach 1:
The patent implements local quality by providing separate pressure application mechanisms for different contact regions. The load connection element has a first pressure application point for the load contact and a second pressure application point for the auxiliary contact, allowing independent optimization of pressure distribution. This ensures that each contact region receives appropriate pressure for its specific function, maintaining both thermal dissipation efficiency and contact uniformity.
3Reliability
If connection elements are designed with multiple contact points, then contact efficiency is improved, but manufacturing precision requirements worsen
Solution Approach 1:
The patent applies equipotentiality by forming both the auxiliary contact and load contact on the same connection element at the same potential level. This ensures that all contact points are equidistant from the substrate surface and experience similar electrical and thermal conditions. The integrated design automatically equalizes the contact conditions, reducing the need for high-precision manual alignment during assembly.
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 design improves electrical output and thermal dissipation by ensuring uniform pressure and contact across the substrate, leading to enhanced service life and performance of the power converter module.
Implementation Method 1
the auxiliary connection elements are designed as contact springs
Implementation Method 2
the substrate is pressed onto a cooling component and thus the heat transfer between the substrate and the cooling component is reliably established
Data Source
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AI summary
The invention describes a pressure-contacted three-phase power converter module comprising a substrate with power semiconductor components for each phase, a housing, a pressure element, and externally extending load and auxiliary connection elements. The substrate consists of an insulating body and conductor tracks with load and auxiliary potentials. The load connection elements are each designed as a metal body with external contact elements, a ribbon-like section, and contact feet extending from this section in three rows. These contact feet extend to the substrate and contact first contact surfaces on conductor tracks with load potential. The auxiliary connection elements are designed as contact springs that contact associated second contact surfaces on conductor tracks with auxiliary potential in the edge region of the substrate and are arranged exclusively in the spaces between two of the three rows of contact feet, which are also located in the edge region.