Switching Cell Connector Layout for Low-Stray-Inductance DC Links
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Solution Overview
Problem
In switching cells for hybrid or electric vehicles, the positioning of power modules and DC link capacitors side by side leads to increased stray inductance due to the distance between connecting tabs, which is not adequately compensated by existing designs, resulting in magnetic field imbalances.
Innovation Solution
A connecting device is interposed between the power module and the DC link capacitor, featuring a connecting part in contact with one polarity tab and a covering part that extends to cover the space between tabs, offset from the connecting part to create a more substantial overlap and compensate for magnetic fields, thus reducing stray inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the power module and DC link capacitor are positioned side by side, then the layout flexibility and ease of installation are improved, but the distance between connecting tabs increases leading to higher stray inductance
Solution Approach 1:
A connecting device is introduced as an intermediary component between the power module and DC link capacitor. This connecting device includes a connecting part that contacts the connecting tab and a covering part that extends to cover the space between tabs, effectively mediating the connection while compensating for the increased distance and reducing stray inductance in the side-by-side layout configuration.
2Ease of manufacture
If connecting tabs are positioned at a distance to maintain clearance and accommodate manufacturing, then manufacturing ease is improved, but magnetic field compensation is insufficient leading to increased stray inductance
Solution Approach 1:
The covering part of the connecting device extends in a direction perpendicular to the connection plane, creating a three-dimensional structure. This dimensional extension allows the covering part to overlap with the space between connecting tabs, providing magnetic field compensation and reducing stray inductance without requiring the connecting tabs themselves to be closer together.
3Reliability
If the connecting tabs are kept separate to maintain polarity isolation, then electrical safety is improved, but the magnetic field compensation is reduced increasing stray inductance
Solution Approach 1:
The connecting device serves as an intermediary that maintains the necessary electrical isolation between connecting tabs of different polarities while simultaneously providing magnetic field compensation. The covering part extends over the space between tabs, creating a path that compensates for magnetic fields without requiring the tabs to be in direct contact or closer proximity.
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 solution effectively secures the connection between the power module and DC link capacitor, minimizing risks of short circuits and significantly reducing stray inductance, enhancing the performance of switching cells in automotive applications.
Implementation Method 1
the connecting device being provided with a connecting part in contact with the connecting tab of the first polarity and a covering part covering at least the space between the connecting tabs, the covering part being offset from the connecting part perpendicularly to the connection plane
Data Source
AI summary
The present invention relates to a switching cell for an automotive vehicle. The switching cell includes at least one power module, a DC link capacitor, and a connecting device between the power module and the DC link capacitor. The power module has at least one connecting tab of a first polarity and at least one connecting tab of a second polarity, the connecting tabs being in a same connection plane and separated by a space. The connecting device includes at least one connecting part in contact with the connecting tab of the first polarity and a covering part covering the space between the connecting tabs, the covering part being offset from the connecting part perpendicularly to the connection plane.