Isolated Converter Power Module Shielding for Higher Power Density
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Solution Overview
Problem
Existing isolated converters face challenges in achieving high power density due to the need for reinforced insulation between high-voltage and low-voltage circuits, which increases volume and reduces efficiency, while alternative layouts complicate manufacturing and increase costs.
Innovation Solution
A power module design that utilizes a shielding structure to transition from reinforced insulation to basic insulation, optimizing the arrangement of high-voltage, transformer, and low-voltage circuits, with a grounded shielding structure to maintain constant potential, reducing safety compliance distances and incorporating ventilation airflow channels for improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reinforced insulation is designed between high-voltage circuit and low-voltage circuit, then safety compliance is improved, but distance between circuits increases and power density is reduced
Solution Approach 1:
A shielding structure is introduced as an intermediary component between the high-voltage circuit and low-voltage circuit. This shielding structure includes a first shielding layer connected to the high-voltage circuit and a second shielding layer connected to the low-voltage circuit, with insulation layers between them. This intermediary shielding arrangement allows the use of basic insulation instead of reinforced insulation, reducing the required distance between circuits while maintaining safety compliance.
2Power
If solid insulation cylinder is used to separate high-voltage and low-voltage circuits, then power density is improved, but manufacturing complexity increases and cost rises
Solution Approach 1:
Instead of using a single solid insulation cylinder, the insulation structure is segmented into multiple independent insulation layers (first insulation layer and second insulation layer) positioned between different shielding layers. This segmentation simplifies manufacturing by allowing each layer to be produced and assembled separately, reducing overall manufacturing complexity while maintaining the required insulation performance and power density.
3Power
If basic insulation is used with sequential arrangement, then power density is improved, but electric field stress increases and partial discharge risk rises
Solution Approach 1:
The shielding structure creates equipotential regions between the high-voltage and low-voltage circuits. The first shielding layer is electrically connected to the high-voltage circuit and the second shielding layer to the low-voltage circuit, with insulation layers maintaining proper potential differences. This equipotential arrangement distributes electric field stress uniformly across the insulation layers, preventing concentration of stress at specific points and reducing partial discharge risk while allowing basic insulation to be used.
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 design increases power density by 15%, simplifies manufacturing, reduces costs, and enhances product reliability and competitiveness by optimizing circuit arrangements and incorporating a grounded shielding structure.
Implementation Method 1
The shielding structure is disposed between the transformer and the second circuit. The second leading wire is electrically connected between the transformer and the second circuit through the shielding structure, and the shielding structure is maintained at a constant potential.
Implementation Method 2
a ventilation airflow channel is formed in the power module of the medium-high-voltage isolated converter for sharing, and combined with the heat sink and the shielding structure in the structural design
Implementation Method 3
combined with the heat sink and the shielding structure in the structural design
Implementation Method 4
combined with the heat sink and the shielding structure in the structural design
Data Source
AI summary
A power module of a medium-high-voltage isolated converter is disclosed. The power module includes a first circuit, a second circuit, a transformer and a shielding structure. A potential of the first circuit is greater than a potential of the second circuit. The transformer includes a first leading wire electrically connected to the first circuit, and a second leading wire electrically connected to the second circuit. The shielding structure is disposed between the transformer and the second circuit. The second leading wire is electrically connected between the transformer and the second circuit through the shielding structure, and the shielding structure is maintained at a constant potential.