Inline Power Converter Module for High-Density Low-Loss Adapters
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Solution Overview
Problem
Existing power distribution systems face challenges in efficiently transmitting power from centralized sources to loads separated by distance, particularly in applications like aviation, portable electronics, and vehicles, due to increasing current demands, material costs, weight limitations, and size constraints, which lead to difficult tradeoffs between transmission efficiency, cost, weight, and size.
Innovation Solution
The use of inline power conversion modules (ICMs) with a module body that includes an input and output opening for accommodating electrical connections, featuring circuitry for power conversion via transformers with fixed voltage transformation ratios, providing voltage transformation and galvanic isolation, and incorporating heat spreading conductive members for thermal management, allowing for compact and efficient power delivery.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher current is used to meet increasing power demands, then power delivery capability is improved, but I2R losses and heat generation increase
Solution Approach 1:
The patent transforms the power delivery approach by changing the voltage parameter. Instead of delivering high power through high current, the system uses isolated power conversion modules that can operate at higher voltages with lower currents, thereby reducing I2R losses while maintaining or improving power delivery capability.
Solution Approach 2:
The power delivery system is segmented into multiple isolated power conversion modules rather than using a single centralized high-current path. This segmentation allows each module to operate independently at optimized voltage and current levels, reducing overall I2R losses in the distribution network.
2Loss of energy
If larger gauge wires are used to reduce I2R losses, then transmission efficiency is improved, but weight and size increase
Solution Approach 1:
The patent changes the operating voltage parameter in power conversion modules, enabling higher voltage operation that allows lower current for the same power level. This parameter change permits the use of smaller gauge wires with adequate current-carrying capacity, reducing weight while maintaining transmission efficiency through reduced I2R losses.
3Power
If more material is used in power harnesses to handle high current, then power delivery capability is improved, but material cost increases
Solution Approach 1:
The patent employs parameter changes by operating power conversion modules at higher voltages with lower currents. This approach maintains power delivery capability while significantly reducing the amount of copper and other materials required in the power harness, thereby reducing material costs.
Solution Approach 2:
By segmenting the power delivery into multiple isolated modules operating at optimized parameters, the system reduces the total material required in the power distribution network while maintaining overall power delivery capability.
4Power
If larger power adapters are used to provide regulated output voltage, then power conversion capability is improved, but size and weight increase
Solution Approach 1:
The patent divides the power conversion function into multiple isolated power conversion modules, each handling a portion of the total power load. This segmentation allows each module to be compact and efficient, and the modules can be distributed throughout the system rather than requiring a single large centralized adapter.
Solution Approach 2:
The patent introduces isolated power conversion modules as intermediary devices between the power source and the load. These modules provide regulated voltage conversion in a distributed manner, eliminating the need for a single large power adapter while maintaining overall power conversion capability.
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 inline power conversion modules enable higher power density, enabling the manufacture of smaller, lighter, and more efficient power adapters that can be conveniently deployed in various applications, reducing the size and weight of power harnesses by allowing higher voltage transfer through smaller gauge wires, thus minimizing material costs and I2R losses.
Implementation Method 1
adapted to convert power received from the input at an input voltage, Vin, for delivery at the output at a unipolar output voltage, Vo, via a transformer
Implementation Method 2
The module body can further include a conductive member electrically connected to an input or output of the first power conversion module and being constructed and arranged to spread heat from the circuitry along a pre-defined region of the module body
Data Source
AI summary
An efficient, high density, inline converter module includes a power conversion circuit and an input wiring harness for connecting the input of the power circuit to a unipolar source. A second wiring harness or electrical connectors may be provided for connecting the output of the power conversion circuit to a load. Connections between a wiring harness and the power conversion circuit may comprise conductive contacts, configured to distribute heat. The power circuit may be over molded to provide electrical insulation and efficient heat transfer to external ambient air. A DC transformer based inline converter module may be used in AC adapter, vehicular, and power system architectures. An input connector for connecting the input wiring harness to the input source may be provided. In some embodiments the input source may be an AC source and the input connector may comprise a rectifier for delivering a rectified, unipolar, voltage to the input of the power conversion assembly via an input wiring harness. By separating the rectifier from the power conversion assembly, the power conversion assembly may be packaged into a smaller volume than would be required if the rectifier, and its associated heat loss, were included in the power conversion assembly.