Power Converter Insulation Layout for Compact Housing
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Solution Overview
Problem
Conventional power converters increase in size due to the need for air insulation between capacitor module terminals and control boards, necessitating larger housings to prevent short circuits.
Innovation Solution
Incorporating a plate-shaped insulating resin between the capacitor module and control board to cover connection terminals, reducing the distance between them and eliminating the need for air insulation, thereby minimizing housing size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air insulation is used between capacitor module terminals and control board, then short circuit prevention is achieved, but housing size increases
Solution Approach 1:
An insulating plate is introduced as an intermediary component between the capacitor module terminals and the control board. This plate provides reliable electrical insulation to prevent short circuits while having minimal impact on the distance between components, thereby avoiding significant increases in housing size.
Solution Approach 2:
The insulating plate is positioned within the existing spatial arrangement of components, nesting the insulation function into the available space between the capacitor module and control board without requiring additional external space that would increase housing dimensions.
2Volume of stationary object
If distance between capacitor module terminal and control board is reduced, then housing size is minimized, but short circuit risk increases
Solution Approach 1:
The insulating plate serves as a mediator that enables reduced spacing between the capacitor module terminal and control board while maintaining adequate electrical insulation. The plate's insulating properties ensure short circuit prevention even when the air gap is minimized, allowing compact housing design.
Solution Approach 2:
The insulation method is changed from relying on air gap distance to using an insulating plate material property. This parameter change allows the distance between components to be reduced while maintaining the same level of electrical insulation reliability.
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
Prevents short circuits and reduces the overall size of the power converter by minimizing the housing dimensions while ensuring secure electrical connections.
Implementation Method 1
a plate-shaped insulating plate located between the capacitor module and the control board so as to cover at least one of the first connection terminal and the second connection terminal and made of an insulating resin
Data Source
AI summary
A power converter includes a semiconductor module, a capacitor module, a control board, and an insulating plate. The capacitor module includes a smoothing capacitor, a first connection terminal electrically connected to the smoothing capacitor and a power supply outside the power converter, and a second connection terminal electrically connected to the semiconductor module. The insulating plate is located between the capacitor module and the control board so as to cover at least one of the first connection terminal and the second connection terminal.