Three-level high-power module combined electrode design
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Solution Overview
Problem
Existing three-level high-power modules have large current loop areas and stray inductance, leading to increased losses due to the small facing area between electrodes, which affects their efficiency and reliability.
Innovation Solution
A three-level high-power module design featuring a combined electrode configuration with parallel and directly facing main body and connection portions of the negative, first intermediate, positive, and second intermediate electrodes, along with insulating layers and strategically arranged arms to reduce current loop areas and stray inductance, and incorporating insulating septums to prevent electrode arc discharge and enhance safety.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the main body portion of the positive electrode and the main body portion of the intermediate electrode are alternatively arranged in parallel, then the structure is simplified, but the facing area between electrodes is small resulting in large current loop area and high stray inductance
Solution Approach 1:
The patent combines the main body portion and connection portion of each electrode into a single integrated structure. The main body portion of the positive electrode is directly connected to its connection portion without separate arrangement, forming a unified electrode assembly that reduces the current loop area while maintaining structural simplicity
Solution Approach 2:
The patent transitions from a planar alternative parallel arrangement to a three-dimensional configuration where the main body portion and connection portion are stacked vertically. The main body portion is positioned above the connection portion, creating a compact vertical structure that reduces the horizontal current loop area while maintaining electrical connectivity
2Ease of manufacture
If the connection portion of the positive electrode is not arranged in parallel to and directly facing the connection portion of the intermediate electrode, then the manufacturing is easier, but the current loop area increases resulting in high loss
Solution Approach 1:
The patent merges the connection portions of adjacent electrodes (positive and intermediate) into a shared common connection region. This unified connection structure eliminates the need for separate parallel arrangement while minimizing the current loop area, thereby reducing power loss without complicating the manufacturing process
Solution Approach 2:
The patent designs the connection portions to be positioned at the same horizontal level and directly facing each other, creating an equipotential arrangement that minimizes the voltage difference and current loop area between adjacent electrodes, reducing resistive losses
3Area of stationary object
If the facing area between electrodes is small, then the electrode structure is compact, but the current loop area becomes large increasing stray inductance and loss
Solution Approach 1:
The patent resolves the contradiction by transitioning from a two-dimensional planar arrangement to a three-dimensional stacked configuration. The main body portion is positioned vertically above the connection portion, allowing the facing area to remain compact while the vertical stacking minimizes the horizontal current loop area, thereby reducing stray inductance
Solution Approach 2:
The patent combines the functional regions of the electrode (main body and connection portions) into a single integrated structure where the main body portion directly overhangs the connection portion. This merging eliminates wasted space and ensures that the compact facing area is efficiently utilized while maintaining a small current loop area
Data Source
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AI summary
A combined electrode comprises a negative electrode, a first intermediate electrode, a positive electrode and a second intermediate electrode, wherein a main body portion (71) of the negative electrode is arranged in parallel to and directly facing a main body portion (81) of the first intermediate electrode, and a connection portion (72) of the negative electrode is arranged in parallel to and directly facing a connection portion (82) of the first intermediate electrode too, and main body portions (91, 92) of the positive electrode are arranged in parallel to and directly facing main body portions (101, 102) of the second intermediate electrode, and a connection portion (93) of the positive electrode is arranged in parallel to and directly facing a connection portion (103) of the second intermediate electrode, thereby increasing a facing area between the negative electrode and the first intermediate electrode and between the positive electrode and the second intermediate electrode, reducing a current loop area between the negative electrode and the first intermediate electrode and between the positive electrode and the second intermediate electrode, and effectively reducing the stray inductance and loss of the combined electrode. Meanwhile, provided is a three-level high-power module using the combined electrode, thereby effectively reducing the stray inductance and the loss of the power module.