Vertical Power Card Switch Alignment for Uniform Cooling
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Solution Overview
Problem
In semiconductor modules with insulated gate bipolar transistors (IGBTs), temperature differences occur between switches due to varying heat exchange efficiencies, leading to potential performance issues.
Innovation Solution
A power card configuration where switches are aligned vertically, covered with a resin portion, and connected via external terminals, allowing for uniform heat exchange with a refrigerant flowing in a lateral direction, thereby suppressing temperature differences between switches.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If switches are arranged in a conventional semiconductor module configuration, then electrical connection is achieved, but temperature differences occur between switches due to varying heat exchange efficiencies
Solution Approach 1:
The patent changes the spatial arrangement of switches from a planar configuration to a vertical alignment along the height direction. This dimensional change allows all switches to be positioned at substantially the same location relative to the cooling unit, enabling uniform heat exchange with the refrigerant flowing in the lateral direction and eliminating temperature differences between switches.
2Temperature
If switches are aligned vertically to improve heat exchange uniformity, then temperature differences are reduced, but manufacturing complexity increases
Solution Approach 1:
The power card is designed as a universal module with a standardized vertical alignment structure that can be integrated into various cooling units. The switches, resin portion, and external connection terminals form a modular assembly that simplifies manufacturing by providing a repeatable configuration, reducing the impact of alignment precision requirements.
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 ensures consistent heat exchange efficiency across switches, reducing temperature differences and enhancing performance by aligning the direction of heat exchange with the flow of refrigerant.
Implementation Method 1
heat exchange with the refrigerant
Data Source
AI summary
A power card, which is to be aligned in a height direction with a cooling unit in which a refrigerant flows in an inner space extending in a lateral direction, includes a plurality of switches, a resin portion, and a plurality of external connection terminals. The switches are aligned in a vertical direction perpendicular to each of the lateral direction and the height direction. The resin portion covers each of the switches. The external connection terminals are electrically connected to the respective switches and each have a portion exposed from the resin portion.