Power Converter PCB Layout to Shrink Reinforced Insulation Boundaries
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Solution Overview
Problem
Existing power conversion devices face challenges in achieving a compact size due to the need for reinforced insulation boundaries that span multiple circuit boards, leading to increased board area and complexity.
Innovation Solution
The solution involves integrating all insulation components, including isolation transformers and photocouplers, onto a single board within the high-power section, allowing for downsized circuit boards by eliminating the need for insulation boundaries across multiple boards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reinforced insulation boundaries are provided across multiple circuit boards to ensure electrical safety, then electrical insulation between high voltage and low voltage parts is improved, but the board area and device size increase
Solution Approach 1:
The patent merges the high-power section and low-power section onto a single circuit board, eliminating the need for reinforced insulation boundaries across multiple boards. The power supply circuit, drive circuit, control circuit, and communication circuit are all integrated on one board, allowing the insulated boundary to be contained within a single board rather than spanning across multiple boards, thus reducing the overall board area while maintaining electrical safety
Solution Approach 2:
The patent repositions the insulated boundary from a horizontal arrangement across multiple boards to a vertical arrangement within a single board. By placing the power supply circuit in the high-power section and the drive/control/communication circuits in the low-power section on the same board, the insulation boundary becomes a vertical separation rather than a horizontal span, reducing the board area required
2Reliability
If reinforced insulation boundaries span multiple circuit boards, then electrical safety is maintained, but device complexity increases
Solution Approach 1:
The patent combines multiple functional sections (power supply, drive, control, communication) onto a single circuit board, eliminating the need for complex multi-board interconnections and reinforced insulation boundaries across board interfaces. This integration simplifies the overall device structure while maintaining electrical safety through proper section separation on the single board
Solution Approach 2:
The patent extracts the communication circuit from the traditional multi-board configuration and integrates it directly onto the same circuit board as the power supply and control circuits. This extraction and integration eliminates the need for complex communication interfaces across insulated boundaries, reducing device complexity while maintaining safety
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 results in a more compact power conversion device design with improved cooling efficiency and simplified assembly, while maintaining reinforced insulation standards.
Implementation Method 1
A power supply circuit that supplies power to the drive circuit and the control circuit; an isolation transformer may be used in the power supply circuit to provide reinforced insulation
Implementation Method 2
The current control microcomputer and the main control microcomputer are reinforced and insulated with a photocoupler or other insulating element in the communication circuit
Data Source
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AI summary
Provided is a power conversion device which comprises a main circuit board, a first board, and a second board and which has a reduced size. The main circuit board has a rectifier circuit and an inverter circuit which are disposed in a high-power section, the rectifier circuit rectifying AC voltage and The second board is provided with a The first board is connected to the main circuit board and to the second board, and is provided with: a first circuit disposed in a low-power section. The second board is provided with a second circuit disposed in a low-power section, section from each other in a reinforced manner; an insulating transformer disposed in the reinforced insulation region and constituting a constituent component of a power supply circuit for receiving the DC voltage and supplying power to the first circuit and to the second circuit; and an insulating element disposed in the reinforced insulation region and allowing a signal to be exchanged between the first circuit and the second circuit.