PCB Power Cell With Integrated Voltage Isolation

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

The construction of modular medium voltage drives is challenging due to the need for significant isolation between conductive components, requiring expensive insulating materials and increasing labor costs, as the output voltage is higher than the individual power cell voltages.

Innovation Solution

A printed circuit board (PCB) power cell with integrated voltage isolation, utilizing a multiple section housing assembly and non-conductive materials, such as glass fiber reinforced plastic, to achieve built-in voltage isolation, allowing for a more compact design and reduced labor costs by eliminating the need for additional insulating materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If additional insulating materials are added to maintain proper isolation between power cells, then voltage isolation is improved, but cost and labor complexity increase

Engineering Contradiction:

Improvevoltage isolationVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The housing assembly integrates multiple functions: it provides mechanical support, structural containment, and voltage isolation between power cells. The non-conductive material is incorporated directly into the housing structure rather than being added as separate insulating components, eliminating the need for additional assembly steps while maintaining proper electrical isolation.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The housing assembly serves multiple purposes simultaneously: it acts as a mechanical enclosure for power cell components, provides structural support, and functions as an electrical insulator between high-voltage power cells. This multi-functionality reduces the number of separate components needed and simplifies the overall assembly process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Reliability

If minimum spacing is maintained between conductive parts, then voltage isolation is improved, but power supply volume increases

Engineering Contradiction:

Improvevoltage isolationVSAvoidpower supply volume

Core Design Contradiction:

ReliabilityVSVolume of stationary object

Solution Approach 1:

The housing assembly combines mechanical support and electrical isolation functions into a single integrated structure. By incorporating non-conductive material directly into the housing, the design eliminates the need for additional spacing between conductive parts of adjacent power cells, as the housing itself provides the necessary electrical insulation.

Inventive Principle:

Principle #5Merging (Combining)

3Reliability

If non-conductive housing material is used, then voltage isolation is improved, but manufacturing cost increases

Engineering Contradiction:

Improvevoltage isolationVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #5Merging (Combining)

Data Source

PatentUS10720851B2Printed circuit board power cell with isolation and medium voltage multi-cell power supply

Publication Date: 2020.07.21 INNOMOTICS GMBH

AI summary

A printed circuit board (PCB) power cell (100) for arranging in a multi-cell power supply (500) includes a housing assembly (102) with a multiple section housing (104, 106), and a PCB assembly (120) positioned within the housing assembly (102), wherein the housing assembly (102) and the PCB assembly (120) are configured to provide an integrated voltage isolation of the power cell (100) which supports an output voltage of the multi-cell power supply (500). Furthermore, a multi-cell power supply (500) including a PCB power cell (100) with isolation is described.