Power Converter Wire Buffering Against Sealing Expansion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In power conversion devices, the uneven heating of wires due to current flow causes thermal expansion of the sealing material, leading to potential insulation breakdown and device failure as different wires with electrodes come into contact.
Innovation Solution
The implementation of buffering members that extend in specific directions, positioned above the peak points of wires, restricts the expansion-induced stress on wires, preventing contact between wires with different electrodes and thus maintaining insulation integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If wires are connected to semiconductor chips and current flows through them, then electrical connections are established and power conversion function is achieved, but wires generate heat causing thermal expansion of sealing material which leads to insulation breakdown and device failure
Solution Approach 1:
The patent introduces a buffering member positioned between the sealing material and the wire to preemptively absorb thermal expansion forces. This buffering member, made of elastic or compressible material, is installed during manufacturing to cushion against future thermal expansion when wires heat up during operation, preventing insulation breakdown before it occurs.
Solution Approach 2:
The buffering member acts as an intermediary element between the heat-generating wire and the sealing material. It mediates the thermal interaction by absorbing expansion forces, preventing direct contact and potential insulation breakdown between the wire and sealing material while allowing the wire to function normally.
2Reliability
If sealing material is used to seal the housing space, then device enclosure and protection are achieved, but thermal expansion of sealing material causes wires to stretch and contact each other leading to insulation breakdown
Solution Approach 1:
The buffering member is installed during manufacturing to preemptively cushion against thermal expansion forces that will occur during operation. This elastic or compressible component absorbs expansion forces before they can cause wires to stretch and contact each other, maintaining insulation integrity without requiring complex active control systems.
3Volume of moving object
If wires are positioned close to each other for compact design, then device size is reduced, but thermal expansion causes wires to contact each other resulting in insulation breakdown and device failure
Solution Approach 1:
The buffering member is strategically positioned near heat-generating wires to provide preemptive cushioning against thermal expansion. This allows wires to be positioned closer together for compact design while the buffering member absorbs expansion forces, preventing wire contact and maintaining insulation integrity despite reduced spacing.
Solution Approach 2:
The buffering member serves as an intermediary protective element between closely positioned wires and the sealing material. It mediates thermal expansion effects, allowing compact wire routing while preventing insulation breakdown through its elastic or compressible properties.
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 solution effectively prevents insulation breakdown and enhances the reliability of power conversion devices by buffering the thermal expansion of the sealing material, reducing the risk of wire contact and improving long-term device performance.
Implementation Method 1
the sealing material around the one set of wires repeats expansion and contraction
Data Source
AI summary
A power conversion device includes a sealing material that fills the housing space of a case and that has a sealing surface located above a peak point of a wire included in a semiconductor unit in a side view of the device. The power conversion device further includes a buffering member that extends in a predetermined direction in plan view of the device and that has a buffering bottom surface located above the peak point of the wire and under the sealing surface in the side view.