Self-Clearing Power Module Indirect Fuse Isolation
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Solution Overview
Problem
Power conversion modules, particularly inverters, face failures due to shorted semiconductor switch dies, which can disable systems and cause damage, as high-power switches have shorter lifetimes than other components, and existing technologies lack effective methods to isolate and clear such failures without causing collateral damage.
Innovation Solution
The implementation of an indirect fusing system using pyrotechnic elements positioned near bond wires or connectors, which are triggered by sensors detecting arc flashes, pressure waves, or other failure consequences to sever conductors and isolate the failed die from the rest of the power module, preventing further damage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If high power semiconductor switches are used for power conversion, then power conversion capability is improved, but component lifetime is reduced and failure risk increases
Solution Approach 1:
The patent segments the power module into isolated sections by introducing indirect fuses that can sever conductors to isolate failed semiconductor switches from the rest of the circuit, allowing other sections to continue operating
Solution Approach 2:
The indirect fuse acts as an intermediary component between the semiconductor switch and the circuit, providing a controlled failure mechanism that prevents direct short circuits and protects other components from damage
2Reliability
If semiconductor switch failure occurs, then system disablement and damage occur, but existing technologies lack effective isolation methods
Solution Approach 1:
The patent extracts the failed semiconductor switch from the circuit by using indirect fuses to sever its conductors, removing the failure source while maintaining the rest of the system operational
Solution Approach 2:
The indirect fuse is designed as a disposable component that sacrifices itself by severing the conductor when triggered, providing a low-cost solution to prevent expensive damage to other system components
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 effectively isolates failed switch dies from the power module, preventing system disablement and damage, allowing continued operation in reduced states and enabling scheduled maintenance, especially crucial for autonomous vehicles that require stability and control without driver input.
Implementation Method 1
The power module includes an indirect fuse element, in the form of a pyrotechnic element, positioned proximate bond wires, bond ribbons, or other connectors
Implementation Method 2
one or more sensors that, in the presence of an arc flash, pressure wave, audible signal, and/or other consequence of a failed switch die
Data Source
AI summary
Aspects of the present disclosure involve a power module, which may include an inverter circuit employing semiconductor switch dies. In the presence of a failure of a die, which may include an arc from a short, a sensor produces a signal responsive to the failure. The signal initiates an indirect fuse, such as a pyrotechnic element, that opens conductors associated with the die. For example, the die or a related die may be wire bonded to terminals of the module. The indirect element may therefore open the bonds to the terminals to isolate the failed die and/or related dies.