DC-DC Converter Metal Frame Shielding and Vibration Fixation
Solution Overview
Problem
The existing DC-DC converter apparatus structure is prone to electromagnetic noise interference and risk of transformer breakage due to shock or vibration, as the transformer is not adequately shielded and secured.
Innovation Solution
A DC-DC converter apparatus design featuring a metal frame between the transformer and control circuit board assembly for electromagnetic noise shielding, and elastic members to securely fix the transformer to the case, reducing the risk of breakage from vibrations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the transformer and control circuit board assembly are placed in the same case without partition, then the device complexity is reduced, but electromagnetic noise from the transformer interferes with the control circuit board assembly
Solution Approach 1:
The case is divided into a high-voltage chamber housing the transformer and a low-voltage chamber housing the control circuit board assembly, with a partition wall separating them. This segmentation isolates the electromagnetic noise source (transformer) from the sensitive control circuits while maintaining overall device integration.
Solution Approach 2:
A metal frame is introduced as an intermediary component between the transformer and the control circuit board assembly. The metal frame acts as an electromagnetic shield, blocking noise transmission while providing structural support, thus resolving the contradiction between integration and noise isolation.
2Reliability
If the transformer is secured with rigid fastening, then the reliability under vibration is improved, but the transformer may break due to shock or vibration
Solution Approach 1:
Elastic members are pre-installed between the metal frame and the transformer to provide cushioning before shock or vibration occurs. These elastic members absorb mechanical shocks and vibrations, preventing direct transmission to the transformer while maintaining reliable fixation under normal operating conditions.
3Stability of the object's composition
If the transformer is pressed and fixed firmly, then the stability under vibration is improved, but the risk of transformer breakage increases
Solution Approach 1:
The fixing mechanism uses elastic members that change their mechanical parameters (stiffness, force) based on operating conditions. Under normal vibration, the elastic members provide sufficient holding force for stability, while under extreme shock, they deform to reduce peak forces, preventing transformer breakage.
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 design effectively shields electromagnetic noise and securely fixes the transformer, enhancing reliability by reducing noise interference and the likelihood of breakage from shocks or vibrations.
Implementation Method 1
an elastic member interposed between the metal frame and the transformer, in which the transformer is pressed and fixed to a bottom portion side of the case by the elastic member interposed between the metal frame and the transformer
Implementation Method 2
a metal frame placed in the case and placed between the transformer and the control circuit board assembly... the electromagnetic noise from a transformer is shielded by a metal frame placed between a control circuit board assembly and the transformer
Data Source
AI summary
Objects of the invention are not to receive influence of an electromagnetic noise from a transformer and to reduce a possibility of breakage caused by shock or vibration. In a DC-DC converter apparatus of the invention, a shielding metal frame 300 is placed between a transformer 250 and a control circuit board assembly 240A housed in a case 101. A plate spring 311 attached to the metal frame 300 is pressed to cores 251 of the transformer 250 to fix the transformer 250 to a bottom portion 101a of the case 101. Heat generated from the transformer 250 is transmitted to the metal frame 300 and the bottom portion 101a of the case 101 and is then radiated.