Insulating Support Structure for Low-Profile Power Conversion Units

Solution Overview

Problem

Conventional power conversion apparatuses require a strong support structure to hold heavy power conversion units, which necessitates the use of metal materials and insulating members, increasing height and assembly complexity.

Innovation Solution

A power conversion apparatus with laterally arranged units supported by insulating members that extend between units, reducing the need for additional insulating members and allowing for a lower profile design, featuring a slide guide system and surface irregularities to enhance creepage distance and stability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If a metal support structure is used to support heavy power conversion units, then structural strength is improved, but the apparatus height increases and assembly complexity increases due to required insulating members

Engineering Contradiction:

Improvesupport structure strengthVSAvoidapparatus height

Core Design Contradiction:

StrengthVSLength of stationary object

Solution Approach 1:

The support structure and insulating function are merged into a single integrated support body made of insulating material. This eliminates the need for separate insulating members between the power conversion units and the support structure, thereby reducing apparatus height while maintaining both mechanical strength and electrical insulation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support body is made of insulating material that provides both mechanical support strength and electrical insulation properties. This composite functionality in a single material eliminates the need for additional insulating components and reduces the overall height of the apparatus.

Inventive Principle:

Principle #40Composite materials

2Strength

If a metal support structure is used to support heavy power conversion units, then structural strength is improved, but device complexity increases due to additional insulating members

Engineering Contradiction:

Improvesupport structure strengthVSAvoidassembly complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The support structure and insulating function are merged into a single integrated support body made of insulating material. This eliminates the need for separate insulating members between the power conversion units and the support structure, thereby reducing apparatus height while maintaining both mechanical strength and electrical insulation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The insulating function is extracted from being a separate component and integrated into the support body itself. This removes the unnecessary element of separate insulating members from the system, simplifying the overall structure and assembly process while maintaining electrical insulation.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If insulating members are added to ensure breakdown voltage, then electrical insulation is improved, but apparatus height increases

Engineering Contradiction:

Improvebreakdown voltageVSAvoidapparatus height

Core Design Contradiction:

ReliabilityVSLength of stationary object

Solution Approach 1:

The support structure and insulating function are merged into a single integrated support body made of insulating material. This eliminates the need for separate insulating members between the power conversion units and the support structure, thereby reducing apparatus height while maintaining both mechanical strength and electrical insulation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The support body serves multiple functions simultaneously: it provides mechanical support strength, ensures electrical insulation (breakdown voltage), and eliminates the need for additional insulating components. This multi-functionality reduces the overall apparatus height while maintaining reliability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12003187B2Power conversion apparatus

Publication Date: 2024.06.04 TMEIC CORP

AI summary

A power conversion apparatus includes a plurality of power conversion units each including a power conversion module, the plurality of power conversion units being arranged at an interval in a lateral direction orthogonal to a vertical direction, and at least one support body that extends from one side toward the other side of the plurality of power conversion units in the lateral direction, on which the plurality of power conversion units are placed from above. The support body is formed from an insulating member.