Insulation Module Layout for 5000 Vrms Gate Driver Isolation
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Solution Overview
Problem
Existing insulation transformers in gate drivers face challenges in effectively insulating high and low-voltage circuits while allowing signal transmission, particularly in applications requiring high insulation voltages such as electric vehicles, where existing designs may not adequately manage the voltage differences and insulation requirements.
Innovation Solution
A gate driver design incorporating transformers that magnetically couple coils to insulate low-voltage and high-voltage circuits, using a configuration with separate coils and insulation layers to manage high insulation voltages, allowing signal transmission while maintaining electrical isolation between circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulation layers are added between primary and secondary coils to increase insulation voltage, then insulation performance is improved, but device complexity and size increase
Solution Approach 1:
The patent uses a composite insulation structure combining multiple materials: insulation varnish coating the coils, insulation paper between coil layers, and insulation paint on the bobbin. This multi-material approach achieves high insulation voltage (5000 Vrms) while maintaining a compact integrated transformer design, resolving the contradiction between insulation performance and device complexity
Solution Approach 2:
The patent implements nested insulation layers within the transformer structure: the primary and secondary coils are wound on a common bobbin with insulation paper between layers, insulation varnish coats the coil surfaces, and insulation paint is applied to the bobbin. This nested arrangement provides comprehensive insulation coverage without increasing overall device size, addressing both insulation requirements and compactness
2Reliability
If insulation layers are added between primary and secondary coils to increase insulation voltage, then insulation performance is improved, but the transformer size increases
Solution Approach 1:
The patent employs thin film insulation materials including insulation varnish (coating the coils), insulation paper (between coil layers), and insulation paint (on the bobbin). These thin flexible insulation layers provide effective electrical isolation for 5000 Vrms applications while adding minimal thickness, thus achieving high insulation performance without significantly increasing transformer size
3Reliability
If separate coils with insulation layers are used to achieve high insulation voltage, then insulation performance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies insulation varnish to the coils before winding, and applies insulation paint to the bobbin before coil assembly. These preliminary insulation treatments ensure that insulation layers are already in place before the coils are wound and assembled together, simplifying the manufacturing process by eliminating the need for post-assembly insulation application and ensuring consistent insulation quality
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 design achieves effective insulation of up to 5000 Vrms, enabling reliable signal transmission between high and low-voltage circuits, suitable for electric vehicle applications, with improved insulation and reduced risk of electrical interference.
Implementation Method 1
a primary coil and a secondary coil that are opposed to each other with an insulation layer interposed between the primary coil and the secondary coil
Data Source
AI summary
This insulation module is provided with: a first conductor and a second conductor, which are buried in an insulating layer so as to face each other at a distance in the thickness direction of the insulating layer; a first electrode which is connected to the first conductor; a second electrode which is connected to the second conductor, while being arranged at a position that is away from the first electrode when viewed from the thickness direction of the insulating layer; a passivation layer which is formed on the surface of the insulating layer; a low dielectric constant layer which is formed on the surface of the passivation layer, and has a lower dielectric constant than the passivation layer; and a mold resin which covers the low dielectric constant layer.