Power Adapter Packaging Galvanic Isolation via Bridge Board
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Solution Overview
Problem
Existing power conversion modules lack efficient methods for achieving galvanic isolation between input and output, which is crucial for safety and minimizing disturbances in power systems.
Innovation Solution
The apparatus includes a power conversion module with a module input and output connected to separate printed circuit boards (PCBs) via galvanically isolated connections, and an isolator board that forms a bridge between the PCBs, ensuring galvanic isolation while allowing power conversion between the input and output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If power conversion modules are used in the same mechanical package with identical or similar lead arrangements, then manufacturing efficiency and space utilization are improved, but achieving galvanic isolation between input and output becomes more difficult
Solution Approach 1:
The patent divides the power conversion system into separate input and output PCBs that are physically separated and connected through an isolator board. This segmentation allows each PCB to be optimized independently while maintaining galvanic isolation, resolving the contradiction between manufacturing efficiency and isolation reliability.
Solution Approach 2:
The isolator board serves as an intermediary component between the input and output PCBs. It provides galvanic isolation while enabling power and signal transmission, thus maintaining both manufacturing efficiency (by using a standardized package) and reliability (through effective isolation).
2Reliability
If separate PCBs are used for input and output to achieve galvanic isolation, then safety and disturbance minimization are improved, but device complexity increases
Solution Approach 1:
The patent merges the isolation function with the power conversion function by integrating the isolator board into the same mechanical package as the input and output PCBs. This combining approach achieves galvanic isolation without requiring completely separate devices, thus reducing overall structural complexity.
Solution Approach 2:
The isolator board performs multiple functions: galvanic isolation, power transmission, and signal transmission. This multi-functionality reduces the need for additional separate components, thereby reducing device complexity while maintaining reliability.
3Adaptability or versatility
If standard mechanical package with identical lead arrangements is used for different power conversion modules, then adaptability and inventory management are improved, but achieving galvanic isolation becomes more challenging
Solution Approach 1:
The patent segments the internal architecture into separate input and output PCBs with standardized leads, while using an isolator board to provide galvanic isolation. This allows different power conversion modules to use the same standard package and lead arrangements for adaptability, while still achieving reliable galvanic isolation through the segmented design.
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 effectively provides galvanic isolation between the input and output of power conversion systems, enhancing safety and reducing disturbances, while enabling efficient power conversion within the same mechanical package.
Implementation Method 1
an isolator board having first terminations electrically connected to the first PCB and second terminations electrically connected to the second PCB, the first terminations being galvanically isolated from the second terminations
Data Source
AI summary
A power adapter package comprises a power conversion module, an input board assembly comprising terminals for receiving power from an input source and delivering power to the input of the power conversion module, an output board assembly for receiving power from the output of the power conversion module and delivering power to a load via output terminations, a signal isolator comprising a bridge board spanning a distance between the input board and the output board, a case comprising top and bottom covers, and end cap assemblies for supporting and insulating input and output terminations. The bridge board may comprise a multilayer substrate comprising galvanically isolated and magnetically coupled transformer windings. The input and output boards may be soldered to contacts formed along a peripheral edge of the power conversion module.