Semiconductor Module With Built-In Linear Regulator And Heat Dissipating Mechanism

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Solution Overview

Problem

The instability of power source voltage generated by rectifying AC voltage and the subsequent heat generation issues in linear regulator circuits make it difficult to provide IC chips with a built-in linear regulator function for driving boost converters, especially when converting high input voltages like commercial AC power to the required 15 V for boost converters.

Innovation Solution

A semiconductor module with a built-in linear regulator function is mounted on a heat dissipating mechanism, which generates a power source voltage for the boost converter while effectively reducing temperature increase and power consumption by using the linear regulator function based on the voltage boosted by the boost converter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a linear regulator circuit is used to generate a power source voltage from high input voltage, then the power source voltage can be stabilized, but heat generation increases causing temperature increase

Engineering Contradiction:

Improvepower source voltage stabilityVSAvoidtemperature increase

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent utilizes the heat generated by the linear regulator circuit to drive a thermoelectric generator, which converts the waste heat into electrical energy. This converted electricity is then used to power the control circuit, thereby transforming the harmful heat generation into a useful resource that eliminates the need for separate power supply circuits.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The system achieves self-powering by using the heat generated during voltage regulation to produce electricity through the thermoelectric generator. The generated electricity automatically powers the control circuit, creating a self-sustaining system where the byproduct of one process (heat) becomes the energy source for another process (control circuit operation).

Inventive Principle:

Principle #25Self-service

2Use of energy by moving object

If a linear regulator function is built into the IC chip, then power consumption is reduced, but heat generation causes temperature increase that limits its applicability

Engineering Contradiction:

Improvepower consumptionVSAvoidtemperature increase

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The patent converts the waste heat generated by the linear regulator into useful electrical energy through a thermoelectric generator. This allows the system to maintain low power consumption while eliminating the detrimental temperature increase, as the heat is repurposed to generate power for the control circuit.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The patent changes the thermal parameter by introducing a thermoelectric generator that converts thermal energy into electrical energy. This parameter transformation allows the system to maintain the beneficial low power consumption state while converting the harmful heat generation into a useful resource.

Inventive Principle:

Principle #35Parameter changes

3Power

If AC voltage is rectified to generate power source voltage, then power can be supplied to the boost converter, but the voltage becomes unstable

Engineering Contradiction:

Improvepower supply capabilityVSAvoidvoltage stability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

The patent introduces a linear regulator circuit as an intermediary between the rectified AC voltage and the boost converter. This intermediary component stabilizes the fluctuating rectified voltage into a stable DC power source voltage, ensuring reliable operation of the boost converter while maintaining power supply capability.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 semiconductor module suppresses temperature increase caused by the linear regulator function, allowing for stable operation and reduced power consumption, enabling the generation of a power source voltage for boost converters from high input voltages.

Implementation Method 1

The voltage generator having the built-in linear regulator function is mounted on the heat dissipating mechanism

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS9479049B2Semiconductor module and boost rectifier circuit

Publication Date: 2016.10.25 MITSUBISHI ELECTRIC CORP

AI summary

A semiconductor module includes a voltage generator, and a heat dissipating mechanism composed of, for example, an insulating heat dissipating sheet and a heat sink. The voltage generator is capable of generating, by using a built-in linear regulator function, a power source voltage to drive a boost converter based on a voltage boosted by the boost converter. The voltage generator is mounted on the heat dissipating mechanism.