Pulse Transformer Layout for Compact Power Converter Assembly
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Solution Overview
Problem
In power conversion devices for electric vehicles, the integration of inverters and DC-DC converters results in unwanted space due to the placement of pulse transformers, leading to a bulky configuration, as they cannot be stored between semiconductor switching elements and the circuit board due to lead terminal restrictions.
Innovation Solution
The use of elongated terminal extension members that match the height of the pulse transformer, allowing it to be placed between the semiconductor switching elements and the circuit board, with insertion guides on the circuit board to facilitate assembly and reduce void space, while ensuring vibration resistance through deformation parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the pulse transformer is mounted on the surface of the circuit board on its side reverse to the insertion guides, then the driving circuit can be formed, but the device becomes even more bulky
Solution Approach 1:
The pulse transformer is relocated from the conventional circuit board surface mounting to the space between the semiconductor switching elements and the circuit board. This spatial reconfiguration utilizes the vertical dimension (thickness direction) to place the transformer, allowing it to extend in the direction from the semiconductor switching elements toward the circuit board without increasing the device's planar footprint.
2Ease of operation
If insertion guides are provided on the circuit board to facilitate electrical connections, then assembly is easier, but unwanted space is produced between the semiconductor switching elements and the circuit board
Solution Approach 1:
The insertion guides are extracted from the conventional position on the circuit board surface and relocated to extend from the semiconductor switching elements. This repositioning allows the guides to occupy the previously wasted space between the switching elements and the circuit board, converting unused volume into functional assembly features that facilitate electrical connections while reducing overall device volume.
3Volume of moving object
If the pulse transformer is placed between the semiconductor switching elements and the circuit board, then the device can be downsized, but the lead terminals of the semiconductor switching elements restrict the available space
Solution Approach 1:
The lead terminals of the semiconductor switching elements are designed with flexible positioning capability, allowing them to be arranged dynamically to accommodate the pulse transformer in the interstitial space. The terminals can be routed or positioned in different configurations to create sufficient clearance for the transformer while maintaining electrical connectivity, thus adapting the terminal layout to the spatial constraints rather than being rigidly fixed.
Data Source
AI summary
A power conversion device includes: semiconductor switching elements; a housing on which the semiconductor switching elements are fixed; a circuit board on which a driving circuit for driving the semiconductor switching elements is mounted and which is located opposite to and spaced apart from a fixing surface; insertion guides which are disposed on an opposing surface of the circuit board relative to the fixing surface; and elongated terminal extension members each having a length that is matched with a height of a pulse transformer, one ends of which are bonded to respective lead terminals, and the other ends of which extend toward the insertion guides; wherein the pulse transformer is disposed on the opposing surface so as to be opposite to major surfaces of the semiconductor switching elements.