Power Module Insulating Board Structure for Transformer Air Gap Control
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Solution Overview
Problem
The efficiency of transformers in power modules is relatively low due to the large air gap in the magnetic core, which is exacerbated by the insulating board penetrating through the air gap, limiting the control over the air gap size and reducing transformer efficiency.
Innovation Solution
The power module design incorporates an insulating board with protrusion portions and connecting bridges that form insulation cavities, allowing at least part of the magnetic core to be set within these cavities or connecting bridges, thereby controlling the air gap size and improving transformer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the insulating board is designed as a flat plate without protrusions, then the structure is simple and easy to manufacture, but the air gap of the magnetic core cannot be controlled and transformer efficiency is low
Solution Approach 1:
The insulating board is segmented into a flat plate portion and at least one protrusion portion, where the protrusion portion extends along the third direction to form an insulation cavity. This segmentation allows the magnetic core to be positioned within the cavity, enabling precise control of the air gap while maintaining structural simplicity for manufacturing.
Solution Approach 2:
The insulating board transitions from a two-dimensional flat plate to a three-dimensional structure by adding the protrusion portion that extends in the third direction (perpendicular to the first and second directions). This dimensional change creates the insulation cavity that accommodates the magnetic core, enabling air gap control without significantly increasing manufacturing complexity.
2Reliability
If the insulating board penetrates through the air gap of the magnetic core, then the insulation is provided, but the air gap size cannot be controlled and transformer efficiency decreases
Solution Approach 1:
The protrusion portion is extracted from the flat plate portion and extended along the third direction to form a separate insulation cavity. This extraction allows the magnetic core to be positioned within the cavity rather than having the insulating board penetrate through the air gap, thereby maintaining both insulation performance and precise air gap control for improved transformer efficiency.
3Manufacturing precision
If the insulating board is made thicker to prevent penetration, then the air gap control is improved, but the overall strength and rigidity may be compromised
Solution Approach 1:
The insulating board is segmented into a flat plate portion for maintaining overall strength and at least one protrusion portion for precise air gap control. The protrusion portion forms an insulation cavity that accommodates the magnetic core, enabling accurate air gap positioning without requiring excessive thickness that would compromise the board's flexibility and overall structural integrity.
Data Source
AI summary
The present application provides a power module, including a first side plate, a second side plate, and an insulating board. The insulating board includes a flat plate portion, at least one protrusion portion, and at least one connecting bridge, the flat plate portion is parallel to a plane formed by a first direction and a second direction; at least one of the protrusion portion and the connecting bridge protrudes along a third direction to form an insulation cavity; the insulating board, the first side plate, and the second side plate in combination form a first accommodating space and a second accommodating space along the third direction, the first accommodating space is provided with a first power device, and the second accommodating space is provided with a second power device; and a transformer, including a magnetic core and a winding wound on the magnetic core.