Terminal Conversion Adaptor for Power Semiconductor Modules

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Solution Overview

Problem

The existing power semiconductor modules require different terminal shapes for various applications, leading to increased production complexity, economic inefficiency due to unnecessary stockpiling of modules with different terminal shapes, and higher manufacturing costs.

Innovation Solution

A conversion adaptor that includes a conductive member with different connection forms and an insulating support member, allowing the power semiconductor module to be easily converted between screw connection and insertion connection forms, reducing the need for multiple module shapes and molds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If power semiconductor modules with different terminal shapes are produced in parallel to meet various application requirements, then adaptability to different applications is improved, but device complexity and manufacturing cost increase due to multiple molds and difficult demand prediction

Engineering Contradiction:

Improveadaptability to different connection formsVSAvoidcomplexity of producing multiple module types

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The invention divides the power semiconductor module system into two independent parts: a standard power semiconductor module with fixed terminal shape and a separate terminal conversion adaptor. The adaptor segment provides the different terminal shapes needed for various applications without requiring multiple module types. This segmentation allows the core module to remain simple while the adaptor handles the variability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal conversion adaptor acts as an intermediary component between the standard power semiconductor module and the external connection system. It converts the standard terminal shape into different connection forms (screw connection, insertion connection, etc.) without requiring changes to the module itself. This intermediary approach maintains manufacturing simplicity while providing adaptability.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If multiple kinds of power semiconductor modules with different terminal shapes are manufactured, then various connection requirements are satisfied, but productivity decreases due to difficult demand prediction and unnecessary stockpiling

Engineering Contradiction:

Improvecapability to meet different connection requirementsVSAvoidmanufacturing efficiency and stock management

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The terminal conversion adaptor is designed as a universal component that can convert a single standard terminal shape into multiple different connection forms. This multi-functionality eliminates the need to manufacture multiple specialized module types, allowing standardization of production while maintaining the ability to meet diverse connection requirements through the adaptor.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Adaptability or versatility

If different terminal shapes are integrated directly into power semiconductor modules, then connection flexibility is improved, but manufacturing cost increases due to multiple molds and higher module production costs

Engineering Contradiction:

Improveconnection form flexibilityVSAvoidmanufacturing cost and mold preparation

Core Design Contradiction:

Adaptability or versatilityVSEase of manufacture

Solution Approach 1:

The invention separates the terminal shape functionality from the power semiconductor module itself, placing it in a distinct adaptor component. This segmentation allows the module to be manufactured with a single mold for the standard terminal shape, while the adaptor (produced separately with different molds) provides the various terminal shapes. This reduces module manufacturing cost while maintaining connection flexibility.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The terminal conversion adaptor serves as an intermediary that bridges the standard module terminal and the application-specific connection requirement. By placing the terminal shape variation in this intermediary component rather than in the module itself, manufacturing complexity and cost are reduced while connection flexibility is preserved.

Inventive Principle:

Principle #24Intermediary (Mediator)

Data Source

PatentUS9832903B2Power semiconductor module device

Publication Date: 2017.11.28 FUJI ELECTRIC CO LTD

AI summary

Second fixation portions of a terminal conversion adaptor are fitted into and engaged with engagement portions abutting on first fixation portions of a power semiconductor module. By use of one common fixation screw, each of the fixation portions and each of the second fixation portions are fixed to a cooler. Pin connection type external connection terminals of the power semiconductor module are connected to conversion terminals (which are provided with screw connection portions) of the terminal conversion adaptor so that the pin connection type external connection terminals can be converted into screw connection. Thus, it is possible to provide a conversion adaptor which can convert a connection form of each external connection terminal of a power semiconductor module easily and a power semiconductor module device in which the connection form of the external connection terminal can be converted into a desired connection form by the conversion adaptor.