Optical Insulation Module with Diffused Light Signal Stabilization
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Solution Overview
Problem
Existing insulation modules for gate drivers face challenges in maintaining stable optical coupling between light emitting and receiving elements due to variations in light intensity, leading to inconsistent driving voltage signals for switching elements, particularly in high-noise environments and varying light conditions.
Innovation Solution
The insulation module incorporates a transparent plastic with inorganic particles that absorb or reflect light from the light emitting element, combined with a reflection member that adjusts light refraction indices and conductive bonding materials to ensure a weakened light state reaches the light receiving element, while the sealing plastic enhances electrical insulation with crepage distances between terminals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If a transparent encapsulant is used to allow light transmission between optical transmitter and receiver, then optical coupling is enabled, but light intensity variations cause unstable signal transmission
Solution Approach 1:
The patent introduces an optical diffuser as an intermediary element between the optical transmitter and receiver. This diffuser mediates the light transmission by scattering and redistributing the light rays, converting direct intense light into diffused light with more uniform intensity distribution, thereby stabilizing the optical signal while maintaining transmission efficiency
Solution Approach 2:
The patent modifies the optical parameters of the transmission path by incorporating materials with specific refractive indices and optical scattering properties. The encapsulant and diffuser are selected to have optical parameters that transform the light propagation characteristics, converting variable intensity light into stable intensity light through controlled scattering and refraction
2Volume of moving object
If electrical terminals are placed close together to reduce module size, then compactness is improved, but electrical insulation between terminals deteriorates
Solution Approach 1:
The patent employs composite encapsulant materials that combine electrical insulation properties with optical transmission capabilities. The encapsulant is formulated as a composite material containing insulating polymers with integrated optical diffusing particles, providing both high dielectric strength for terminal insulation and appropriate optical scattering for signal stability
Solution Approach 2:
The encapsulant acts as an intermediary insulating barrier between electrical terminals, allowing close terminal placement while maintaining adequate creepage distances. The encapsulant material provides the necessary electrical insulation properties to prevent breakdown even when terminals are positioned closely together for compactness
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 stabilizes the light received by the light receiving element, reducing processing load and ensuring consistent driving voltage signals, while improving electrical insulation and thermal management, thus enhancing the reliability of the gate driver module.
Implementation Method 1
a transparent plastic 60 with inorganic particles 65 that absorb or reflect light from the light emitting element
Implementation Method 2
a transparent plastic 60 with inorganic particles 65 that absorb or reflect light from the light emitting element
Implementation Method 3
a reflection member 70 that adjusts light refraction indices
Data Source
AI summary
An insulation module includes: a light-emitting element; a light-receiving element that receives light from the light-emitting element; a first die pad on which the light-emitting element is mounted; a second die pad that is provided in alignment with the first die pad and on which the light-receiving element is mounted; a transparent resin that at least covers both the light-emitting element and the light-receiving element; a reflection member that covers at least the transparent resin and is formed from a material that reflects light from the light-emitting element; and an encapsulation resin that encapsulates the reflection member as well as the transparent resin and is formed from a material having a light-blocking effect. At least one of the reflection member and the transparent resin includes inorganic particles that absorb or reflect light from the light-emitting element.