Stacked Power Module Composite for Vibration Resistance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric rotating machines face issues with low vibration resistance and large mounting area requirements due to the disconnection of wire bonding portions and the low vibration resistance of electronic components, leading to reliability concerns and increased size of the power module composite.
Innovation Solution
The electric rotating machine incorporates a power module composite with switching devices molded in insulating resin, a driver module with a control circuit molded in insulating resin, and a heat sink for cooling, where the driver module is superimposed on the power module closer to the heat sink, enhancing vibration resistance and reducing the overall size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If electronic components are sealed with protection gel, then mechanical protection is improved, but wire bonding portion disconnection occurs due to vibration
Solution Approach 1:
The patent changes the physical state of the sealing material from a soft gel-like substance to a hardened resin material. This parameter change allows the sealing material to provide both mechanical protection and vibration resistance, as the hardened resin maintains structural integrity under vibrational stress while still protecting the internal components.
Solution Approach 2:
The patent uses a composite sealing structure that combines resin material with specific structural features. The resin-impregnated cardboard member creates a composite structure that provides both protection and vibration resistance, overcoming the limitations of pure gel sealing.
2Ease of manufacture
If electronic components are arranged on the same plane, then ease of assembly is improved, but mounting area increases
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement of electronic components to a three-dimensional stacked configuration. The driver module is positioned on a different plane (higher position) than the power module, utilizing the vertical dimension to reduce the horizontal mounting area while maintaining assembly feasibility.
3Ease of manufacture
If driver module is positioned on the same plane as power module, then ease of assembly is improved, but power module composite size increases
Solution Approach 1:
The patent positions the driver module in the vertical dimension above the power module rather than arranging them side-by-side on the same plane. This three-dimensional stacking reduces the horizontal footprint and overall volume of the power module composite while keeping the assembly process relatively simple.
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 configuration enhances the vibration resistance and reliability of the power module composite, allowing for downsizing of the electric rotating machine while maintaining operational integrity and reducing the risk of wire bonding failures.
Implementation Method 1
a heat sink that is mounted in the housing and refrigerates the switching devices
Implementation Method 2
switching devices included in the electric-power conversion circuit are molded with an insulating resin
Data Source
AI summary
A power module composite includes a power module (34) in which switching devices (32) included in an electric-power conversion circuit are molded, a driver module (37) that includes a control circuit (35) for controlling the switching devices (32) and is molded, a housing (39) containing the power module (34) and the driver module (37), and a heat sink (38) that is fixed to the housing (39) and refrigerates the switching devices (32); the power module 34 and the driver module 37 are mounted in that order on the heat sink (38) in such a way as to be superimposed on each other.