Modular Power Conversion System Galvanic Insulation
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Solution Overview
Problem
High voltage applications face challenges with transformer insulation due to size, complexity, and flammability issues in oil-filled transformers, and dry-type transformers are more expensive and prone to partial discharge breakdowns.
Innovation Solution
A modular power conversion system with galvanically isolated high frequency AC links using transformers and power converter bridges, where an insulating tube with high dielectric strength spans multiple building blocks, and conductive or semiconductive layers are used to minimize potential gradients and reduce partial discharge effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If oil-filled transformers are used for high voltage applications, then dielectric strength and insulation performance are improved, but flammability and safety issues worsen
Solution Approach 1:
The patent extracts and removes the oil-filled insulation system from the transformer design, replacing it with a dry-type insulation structure using solid dielectric materials and insulating barriers. This eliminates the flammability hazard while maintaining insulation performance through alternative dielectric arrangements.
Solution Approach 2:
The patent introduces intermediate insulating barriers and dielectric structures between high-voltage components, using solid insulating materials as mediators to provide the necessary electrical isolation without relying on flammable oil. These intermediate structures include insulating barriers, spacers, and solid dielectric layers.
2Object-affected harmful factors
If dry-type transformers with solid insulating materials are used, then flammability issues are resolved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent segments the insulation system into discrete, modular components such as individual insulating barriers, spacers, and dielectric layers that can be manufactured separately and assembled systematically. This modular approach simplifies manufacturing by allowing standardized production of insulation components.
Solution Approach 2:
The patent changes the physical and electrical parameters of the insulating materials and their arrangement, optimizing dielectric strength, breakdown voltage, and thermal properties to achieve reliable insulation with simpler manufacturing processes compared to traditional epoxy-filled designs.
3Weight of stationary object
If high frequency operation is used, then transformer size and weight are reduced, but insulation requirements become more stringent
Solution Approach 1:
The patent employs composite insulation structures combining multiple dielectric materials with complementary properties, such as solid insulators with specific breakdown strengths, thermal stability, and frequency-dependent dielectric characteristics. These composite structures provide enhanced insulation reliability for high-frequency operation while maintaining compact transformer dimensions.
Solution Approach 2:
The patent addresses insulation challenges in high-frequency compact transformers by introducing additional spatial dimensions and layered dielectric structures, arranging insulating barriers in multiple layers and orientations to achieve adequate creepage distances and breakdown strength within reduced physical envelopes.
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
This solution reduces the size and weight of transformers, minimizes electromagnetic interference, and enhances structural and dielectric integrity, while avoiding the drawbacks of oil-filled transformers by using a high dielectric strength tube and conductive layers to manage potential gradients.
Implementation Method 1
The high frequency link is magnetically coupled through the transformers in the building blocks but electrically insulated from the building blocks with a tube of high dielectric strength
Implementation Method 2
The high frequency link is magnetically coupled through the transformers in the building blocks
Data Source
AI summary
A modular power conversion system is provided which includes a plurality of building blocks comprised of transformers and power conversion bridges, and a high frequency AC link that transfers power and provides galvanic isolation between the building blocks. The high frequency link includes an insulating tube separating an AC link conductor and the building blocks. The insulating tube is further provided with conductive or semiconductive layers on its inner and outer surfaces for referencing them to the electric potentials of the adjacent conductors and windings, thereby placing the high electric fields substantially directly across the tube and reducing electric fields and partial discharge or corona in the adjoining space or media. The building blocks may be arranged in multiple stacks for DC or AC interface, preferably with neutral or lower voltage connections at the outer edges of the stacks and higher voltage terminals at the centers of the stack.