Substrate Conductive Patterns for Power Converter Connector Relocation
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Solution Overview
Problem
Existing power converters face inefficiencies and increased costs when design modifications are required due to repositioning of connectors, as existing solutions often necessitate changes to internal component layouts and busbar configurations, leading to time and cost losses.
Innovation Solution
The power converter incorporates conductive patterns formed on a substrate, allowing for flexible repositioning of connectors by modifying these patterns, thereby reducing the need for extensive redesign of busbars and internal layouts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If connectors are repositioned in existing power converters, then connector position flexibility is improved, but design complexity and cost increase due to required modifications of internal component layouts and busbar configurations
Solution Approach 1:
The invention divides the electrical connection system into modular components: a substrate with integrated conductive patterns, separate connector assemblies, and distinct functional modules (rectifier, inverter, control circuit). This segmentation allows connectors to be repositioned independently without requiring complex redesign of the entire internal layout, as each module can be configured separately on the substrate.
Solution Approach 2:
The substrate acts as an intermediary element between connectors and internal components. The conductive patterns on the substrate provide flexible electrical interconnection, allowing connectors to be repositioned while the substrate's conductive network adapts the electrical connections accordingly, eliminating the need for complex busbar reconfigurations.
2Adaptability or versatility
If connectors are repositioned in existing power converters, then adapter compatibility is improved, but time and cost losses occur due to additional design modifications
Solution Approach 1:
The substrate with integrated conductive patterns serves multiple functions: it provides electrical connections for power components, supports various connector positions, and enables different adapter configurations. This multi-functionality allows the same basic design to accommodate multiple adapter types and connector positions without requiring separate design modifications for each configuration.
Solution Approach 2:
The electrical connection system is designed to be dynamic rather than fixed. The conductive patterns on the substrate can be configured to connect to connectors at different positions, allowing the system to adapt to different adapter requirements. This dynamic configurability reduces the need for time-consuming redesign modifications when adapting to different connectors.
3Reliability
If traditional busbar configurations are used, then electrical connection stability is improved, but design flexibility for connector repositioning deteriorates
Solution Approach 1:
The invention replaces the traditional mechanical busbar system with a substrate-based electrical connection system. Instead of using rigid busbars that require physical reconfiguration for connector repositioning, the conductive patterns on the substrate provide flexible electrical interconnection. This substitution maintains electrical connection stability through reliable solder joints and conductive traces while enabling easy connector repositioning by simply changing the connection points on the substrate.
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 approach enables flexible design modifications without significant increases in time or cost, allowing for efficient repositioning of connectors and maintaining performance by using substrate-integrated conductive patterns.
Implementation Method 1
a cooler for cooling the plurality of switching elements
Data Source
AI summary
A power converter includes a capacitor and a substrate on which a plurality of switching elements for power conversion are mounted. The power converter includes a cooler for cooling the plurality of switching elements and a housing that accommodates the capacitor, the substrate, and the cooler. The power converter includes a power connector exposed from the housing and an output connector exposed from the housing. The power converter includes a plurality of lines that include a plurality of power lines each electrically connected to the capacitor, given switching elements, and the power connector. The plurality of lines include a plurality of output lines each electrically connected to given switching elements and the output connector. At least one among the plurality of lines is a line that includes a conductive pattern formed on the substrate.