Stacked Insulating Side Walls for Power Modules
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Solution Overview
Problem
Existing power semiconductor modules face high production costs and are prone to explosive destruction due to high voltages during faults, particularly in high voltage direct current transmission and Flexible AC Transmission Systems, where series connections result in high voltage across individual modules, risking explosive damage.
Innovation Solution
The power semiconductor module features a stackable, electrically insulating side wall composed of partial elements with butt joints and connecting bars, made from fiber-reinforced plastic, which provides enhanced explosion resistance and simplified assembly, while maintaining low production costs, with reinforcing ribs and complementary cutouts to seal explosion gases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the insulating side wall is constructed as a single piece, then the structural integrity and explosion resistance are improved, but the production cost increases and assembly complexity increases
Solution Approach 1:
The insulating side wall is divided into multiple stacked insulating partial elements instead of being a single piece. This segmentation allows each partial element to be manufactured separately and assembled into the final side wall structure, reducing production costs while maintaining the overall structural integrity and explosion resistance through the stacked configuration
2Strength
If the insulating side wall is constructed as a single piece, then the structural integrity is improved, but the assembly complexity and difficulty of connecting bars increase
Solution Approach 1:
The side wall is segmented into multiple stackable partial elements with contact areas that rest against one another. This segmentation simplifies assembly by allowing partial elements to be stacked and connected sequentially, reducing the complexity of integrating connecting bars compared to a monolithic structure
Solution Approach 2:
The stacked partial elements are arranged in a nested-like configuration where each partial element contacts the next, creating a layered structure that simplifies assembly while maintaining structural integrity. The connecting bars pass through these stacked elements in a simplified manner compared to a single-piece construction
3Ease of operation
If connecting bars pass through the side wall, then electrical connection is achieved, but explosion gases can escape through the connecting bar paths
Solution Approach 1:
Insulating partial elements serve as intermediaries between the connecting bars and the external environment. These partial elements are positioned around the connecting bars and rest against one another in a stacked configuration, creating a barrier that prevents explosion gases from escaping through the connecting bar pathways while allowing electrical connections to be maintained
Data Source
AI summary
A power semiconductor module includes at least two interconnected power semiconductor units having actuatable power semiconductors, a module housing in which the power semiconductor units are disposed and which has an electrically insulating side wall, and at least one connection bus extended through the side wall and connected to at least one of the power semiconductor units. High explosion resistance and particularly inexpensive production are provided by forming the insulating side wall as a stack of insulating and partial elements constructed as a single piece, in which contact areas of the partial elements contact each other.