Monolithic Insulator for Power Module Voltage Isolation
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Solution Overview
Problem
Existing power supply devices for electric vehicles face challenges in managing ripple currents and providing effective voltage isolation between power modules and capacitors, leading to inefficiencies and potential overheating in electric drive systems.
Innovation Solution
The integration of a power module with inverting circuitry and a capacitor, both encapsulated in a monolithic non-metal insulating material, which absorbs ripple currents and limits voltage variation, while a cooling manifold adjacent to the components helps in heat management, providing both voltage and thermal isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If power modules and capacitors are placed adjacent to each other for compact design, then space utilization is improved, but voltage isolation between components becomes difficult to achieve
Solution Approach 1:
A monolithic non-metal insulating material is introduced as an intermediary substance between the power module and capacitor. This material fills the space between adjacent components while providing the necessary electrical isolation, allowing compact arrangement without compromising voltage isolation reliability
Solution Approach 2:
The patent employs a composite structure where metal components (power module, capacitor) are combined with a non-metal insulating material. This composite approach enables simultaneous achievement of compact spacing and effective voltage isolation by integrating structural and insulating functions in a unified assembly
2Volume of moving object
If power modules and capacitors are placed adjacent to each other for compact design, then space utilization is improved, but thermal management becomes challenging
Solution Approach 1:
The monolithic insulating material provides localized thermal management properties adjacent to heat-generating components. The material can be formulated with specific thermal conductivity characteristics tailored for each component's thermal requirements, enabling effective heat dissipation in compact configurations
Solution Approach 2:
The composite structure of metal components embedded in non-metal insulating material creates pathways for thermal management. The insulating material can incorporate thermal conductive fillers or be designed with specific thermal properties to manage heat from adjacent power modules while maintaining electrical isolation
3Strength
If traditional metal housing is used for structural support, then mechanical strength is improved, but electrical isolation between adjacent components deteriorates
Solution Approach 1:
The patent replaces traditional metal mechanical housing with a monolithic non-metal insulating material that provides both structural support and electrical isolation. This substitution eliminates the need for separate metal housing and insulating barriers, achieving both mechanical strength and electrical isolation through a single material system
Solution Approach 2:
The non-metal insulating material serves multiple functions simultaneously: it provides structural support, electrical isolation, and thermal management. This multi-functional approach replaces the need for separate metal housing and insulating components, achieving both mechanical strength and electrical isolation in a unified structure
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 configuration enhances electrical efficiency by stabilizing voltage and managing heat effectively, improving the reliability and performance of electric vehicle power supply systems by reducing voltage fluctuations and thermal issues.
Implementation Method 1
The capacitor is arranged to absorb ripple currents generated by the power module and limit voltage variation at the inverting circuitry input
Implementation Method 2
The inverting circuitry and the capacitor are over molded with and encapsulated by a monolithic non-metal insulating material that provides voltage isolation between the power module and the capacitor
Implementation Method 3
a cooling manifold adjacent to the inverter and the capacitor bus... providing both voltage and thermal isolation
Data Source
AI summary
A power supply is provided. The power supply device includes a power module and a capacitor. The power module includes inverting circuitry and is configured to deliver electrical power to an electric machine. The capacitor is disposed adjacent to the power module and is arranged to limit voltage variation at the inverting circuitry input due to ripple current. The inverting circuitry and the capacitor are surrounded by a monolithic non-metal casing that provides voltage isolation between the power module and the capacitor.