Floating Intermediate Electrode Isolator for Gate Driver Insulation
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Solution Overview
Problem
Existing gate drivers face challenges in efficiently transmitting control signals between low-voltage and high-voltage circuits while maintaining insulation and preventing direct current voltage leakage, which is crucial for safe operation in high-voltage applications such as electric vehicles.
Innovation Solution
A gate driver configuration that includes a capacitor isolator to insulate low-voltage and high-voltage circuits, using a capacitor with floating intermediate electrode portions to allow signal transmission while preventing direct current voltage leakage, and a semiconductor chip package design that separates and insulates the circuits using encapsulation resin and lead frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the number of insulation layers is increased to improve insulation voltage and dielectric strength, then the insulation performance is improved, but the manufacturing complexity and warpage risk increase
Solution Approach 1:
The patent transitions from increasing insulation layers in the vertical direction to increasing separation distance in the lateral direction. The capacitor chip is positioned laterally between the low-voltage and high-voltage circuits, providing insulation through horizontal separation rather than vertical stacking. This dimensional change resolves the contradiction by achieving high insulation performance without increasing structural complexity.
2Reliability
If the separation distance between low-voltage and high-voltage circuits is increased to improve insulation, then the insulation voltage is improved, but the area occupied by the gate driver increases
Solution Approach 1:
The capacitor chip is nested within the gate driver structure, positioned between the low-voltage and high-voltage circuits. This nested arrangement provides effective insulation through the capacitor chip's dielectric structure while utilizing the existing vertical stacking space, thereby achieving high insulation voltage without significantly increasing the lateral footprint of the gate driver.
3Reliability
If intermediate electrode portions are added to increase separation distance, then the dielectric strength is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The intermediate electrode portions are merged with the capacitor chip structure, forming an integrated component. The capacitor chip includes both the capacitor electrodes and the intermediate electrode portions that provide separation between low-voltage and high-voltage circuits. This merging eliminates the need for separate intermediate electrode structures, simplifying the manufacturing process while maintaining enhanced dielectric strength.
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 solution ensures reliable and safe transmission of control signals between low-voltage and high-voltage circuits, maintaining insulation and preventing direct current voltage leakage, thereby enhancing the safety and efficiency of high-voltage circuit operations.
Implementation Method 1
a capacitor chip with a unique insulation structure, utilizing intermediate electrode portions to increase separation distances and improve dielectric strength
Data Source
AI summary
An isolator includes an insulation layer and a capacitor embedded in the insulation layer. The capacitor includes: a first electrode portion arranged in the insulation layer and connected to a first pad; a second electrode portion arranged in the insulation layer and connected to a second pad; and an intermediate electrode portion arranged in the insulation layer and not connected to the first electrode portion and the second electrode portion. The intermediate electrode portion includes a first intermediate layer, a second intermediate layer, and a connector connecting the first intermediate layer and the second intermediate layer. The capacitor is formed by coupling the first electrode portion and the second electrode portion through the intermediate electrode portion.