Segmented Busbar Terminals for Balanced Current Sharing
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Solution Overview
Problem
In power semiconductor modules for high current applications, the concentration of heat generation at fastening points due to uneven current distribution leads to local hotspots, as existing laminate busbars provide only a single fastening point for terminal electrodes at the same potential level.
Innovation Solution
A main circuit wiring member with a laminate busbar design featuring multiple flat conductors layered through insulators, including step-like bent terminals with hole portions for balanced current distribution across multiple fastening points, reducing heat generation imbalance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple fastening points are provided for terminal electrodes at the same potential level, then the current carrying capacity is improved, but heat generation becomes concentrated locally at fastening points with greater current flow
Solution Approach 1:
The terminal electrode is divided into multiple segmentation portions along the current flow direction, with each portion connected to a separate fastening point. This segmentation distributes the current across multiple connection points, preventing local heat concentration while maintaining high current carrying capacity.
Solution Approach 2:
Different fastening points are positioned at different locations relative to the terminal electrode, creating local variations in current distribution. The terminal electrode structure is designed so that current flows through different paths to different fastening points, balancing the current sharing and heat generation across all connection points.
2Device complexity
If a single fastening point is provided for terminal electrodes, then the device complexity is reduced, but the current sharing balance deteriorates
Solution Approach 1:
The terminal electrode is segmented into multiple portions, each connected to a separate fastening point. This segmentation enables balanced current distribution across multiple connection points, improving current sharing balance and reliability while maintaining a relatively simple overall structure.
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
The solution effectively balances current sharing across multiple fastening points, reducing heat generation imbalance and improving the reliability of power conversion devices.
Implementation Method 1
when a different amount of current flows through each of the fastening points, heat generation becomes concentrated locally at a fastening point where a greater amount of current flows
Data Source
AI summary
A busbar includes an opening, a first terminal, and a second terminal. The first terminal includes a first terminal piece with a step-like bent shape, in which the first terminal piece is bent from a conductor along a bending line, and a plurality of hole portions formed on the first terminal piece and arrayed in a direction parallel to the bending line. The second terminal includes a second terminal piece with a step-like bent shape, in which the second terminal piece is bent from a conductor along a bending line, and a plurality of hole portions formed on the second terminal piece and arrayed in a direction parallel to the bending line. The busbar balances the current sharing in a current that flows through a plurality of fastening points.