Power Semiconductor Module Current Sensor Rotation Bar Alignment

Solution Overview

Problem

The existing power semiconductor modules require different current sensor modules for varying busbar thicknesses, leading to inaccurate sensing and increased tooling costs due to the need for multiple module designs.

Innovation Solution

A power semiconductor module design featuring an electrically insulative frame with a receptacle and a rotation bar that allows a single type of current sensor module to be used across different busbar thicknesses, enabling free rotation for accurate alignment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If different current sensor modules are used for different busbar thicknesses, then current sensing accuracy is improved, but device complexity and tooling costs increase

Engineering Contradiction:

Improvecurrent sensing accuracyVSAvoidnumber of current sensor module types

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The current sensor module is designed with a universal receptacle structure that can accommodate busbars of different thicknesses. The receptacle includes adjustable positioning elements and a rotation bar mechanism that allows the same sensor module to be properly aligned with various busbar dimensions, eliminating the need for multiple specialized sensor module designs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The current sensor module incorporates a rotation bar that can rotate about an axis to dynamically adjust the alignment between the sensor and the busbar. This dynamic adjustment capability allows the sensor module to adapt to different busbar thicknesses and positions, maintaining accurate current sensing across varying configurations without requiring multiple fixed-design sensor modules.

Inventive Principle:

Principle #15Dynamics

2Measurement precision

If different current sensor modules are used for different busbar thicknesses, then current sensing accuracy is improved, but manufacturing costs increase

Engineering Contradiction:

Improvecurrent sensing accuracyVSAvoidtooling cost

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The current sensor module is designed with a universal receptacle structure that can accommodate busbars of different thicknesses. The receptacle includes adjustable positioning elements and a rotation bar mechanism that allows the same sensor module to be properly aligned with various busbar dimensions, eliminating the need for multiple specialized sensor module designs.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If the current sensor module is fixed in position, then manufacturing precision is improved, but adaptability to different busbar thicknesses deteriorates

Engineering Contradiction:

Improvealignment precisionVSAvoidcompatibility with different busbar thicknesses

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The current sensor module incorporates a rotation bar that can rotate about an axis to dynamically adjust the alignment between the sensor and the busbar. This dynamic adjustment capability allows the sensor module to adapt to different busbar thicknesses and positions, maintaining accurate current sensing across varying configurations without requiring multiple fixed-design sensor modules.

Inventive Principle:

Principle #15Dynamics

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 design ensures accurate current sensing regardless of busbar thickness, reducing the need for multiple module types and associated costs while maintaining alignment tolerances.

Implementation Method 1

a first rotation bar jutting out from a first sidewall of the receptacle and onto the exposed part of the busbar without obstructing the opening in the busbar, wherein the first rotation bar forms an axis of rotation within the receptacle

Methodology Applied

Scientific EffectRotation:

Implementation Method 2

a core-less in-phase current sensor is a magnetic sensor that implements one or more sensing elements in close proximity to a current rail such that a measurement can be obtained based on a magnetic field produced by a current flowing through the current rail

Methodology Applied

Scientific EffectMagnetic field sensing: Magnetic Field

Data Source

PatentUS11874303B2Power semiconductor module with current sensor rotation bar

Publication Date: 2024.01.16 INFINEON TECHNOLOGIES AG

AI summary

A power semiconductor module includes: an electrically insulative frame having opposite mounting sides and a border wall that defines a periphery of the frame; a substrate seated in the frame; power semiconductor dies attached to the substrate; signal pins attached to the substrate and electrically connected to the power semiconductor dies; a busbar attached to the substrate and extending through the border wall; a receptacle in the border wall configured to receive a current sensor module and that exposes part of the busbar, the exposed part of the busbar having an opening; and a rotation bar jutting out from a sidewall of the receptacle and onto the exposed part of the busbar without obstructing the opening in the busbar, wherein the rotation bar forms an axis of rotation within the receptacle. A power electronic assembly that incorporates the power semiconductor module and corresponding method of production are also described.