Resistance Alloy Contact Element for Power Electronics Substrate
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Solution Overview
Problem
Current power electronics systems require separate shunt components for current measurement, which occupy significant space and require additional cooling efforts, making them inefficient in terms of space usage and cooling management.
Innovation Solution
Integrating a resistance alloy contact element that serves both as a connection to the electrical conductor and a shunt, eliminating the need for separate shunt components and utilizing existing cooling structures, with the resistance alloy having a low linear temperature coefficient for accurate current measurement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If separate shunt components are used for current measurement, then current measurement can be achieved, but installation space increases and cooling requirements increase
Solution Approach 1:
The contact element is formed from resistance alloy material that serves dual functions: both as an electrical connector and as a shunt for current measurement. This merging of functions eliminates the need for separate shunt components, directly reducing installation space while maintaining current measurement capability
Solution Approach 2:
The contact element is designed to perform multiple functions simultaneously: electrical connection between the power electronics substrate and external conductor, and current measurement through its resistance properties. This multi-functionality allows the same component to serve both connection and measurement purposes, reducing overall system complexity and space requirements
2Measurement precision
If separate shunt components are used for current measurement, then current measurement can be achieved, but cooling requirements increase
Solution Approach 1:
The contact element integrates the shunt function into the existing electrical connection structure, so that the same component that carries current also measures it. This eliminates separate shunt components that would generate additional heat requiring separate cooling infrastructure
Solution Approach 2:
The existing cooling system designed for the power electronics substrate automatically serves to cool the contact element when it is formed from resistance alloy. The contact element utilizes the cooling infrastructure already in place for the substrate, eliminating the need for additional dedicated cooling measures for the shunt
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 solution enables efficient current measurement with reduced installation space and minimal additional cooling requirements, as the contact element can function as both a connection and a shunt, leveraging existing cooling systems for power electronics substrates.
Implementation Method 1
the contact element is formed from a resistance alloy... the resistance alloy expediently features a low linear temperature coefficient of resistance over wide temperature ranges
Implementation Method 2
a current measurement may be necessary. Shunts (shunt resistors) are often used for this purpose
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
Arrangement (1) comprising a power electronics substrate (2) comprising an electrically insulating base plate (4) and an electrically conductive surface layer (6) arranged on one side (5) of the base plate (4), and comprising a contact element (3) whose first end (10) is electrically connected to the surface layer (6) and whose second end (11) is connectable or connected to an electrical conductor (9), wherein the contact element (3) is formed from a resistance alloy.