Power Module Insulating Board Layout for Transformer Air Gap Control
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Solution Overview
Problem
The efficiency of transformers in existing power modules is relatively low due to the larger size of the air gap in the magnetic core, which is caused by the insulating board penetrating through the air gap, limiting the flexibility in adjusting the air gap size.
Innovation Solution
The power module design includes an insulating board with protrusion portions and connecting bridges that form insulation cavities, allowing at least part of the magnetic core to be set within these cavities or bridges, thereby controlling the size of the air gap and improving transformer efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the insulating board is designed as a flat plate structure, then the manufacturing is simple, but the transformer efficiency is low due to large air gap
Solution Approach 1:
The insulating board is segmented into a flat plate portion and multiple protrusion portions. The protrusion portions extend along the thickness direction to form insulation cavities that accommodate the magnetic core, preventing the flat plate from penetrating through the air gap. This segmentation maintains manufacturing simplicity while improving transformer efficiency by controlling the air gap size.
Solution Approach 2:
The magnetic core is nested within the insulation cavities formed by the protrusion portions of the insulating board. This nesting arrangement allows the magnetic core to be positioned precisely without the insulating board penetrating through it, thereby controlling the air gap size and improving transformer efficiency while maintaining structural integration.
2Loss of energy
If the insulating board thickness is increased to reduce air gap, then the transformer efficiency improves, but the module volume increases
Solution Approach 1:
Instead of increasing the overall thickness of the insulating board, the board is segmented with protrusion portions that locally extend into the insulation cavities. This allows precise control of the air gap size at critical locations without proportionally increasing the entire module volume, thus improving transformer efficiency while maintaining compact dimensions.
Solution Approach 2:
The insulating board exhibits local quality variations through the protrusion portions that differ in shape and position. These localized structural variations enable precise control of the air gap at specific locations where it most affects transformer efficiency, without uniformly increasing the board thickness and module volume.
3Loss of energy
If the protrusion portions are added to the insulating board, then the transformer efficiency improves through better air gap control, but the device complexity increases
Solution Approach 1:
The insulating board is divided into a flat plate portion and multiple protrusion portions with different shapes and positions. This segmentation enables the protrusion portions to be optimized for specific functions (controlling air gap, forming insulation cavities) while the flat plate portion maintains structural support, achieving better transformer efficiency without excessive overall complexity.
Solution Approach 2:
The protrusion portions serve multiple functions: they form the insulation cavities that accommodate the magnetic core, control the air gap size, and provide mechanical support. This multi-functionality reduces the need for additional separate components, thereby improving transformer efficiency without proportionally increasing device complexity.
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 design enhances the efficiency of the transformer by allowing flexible adjustment of the air gap size and improves the overall strength of the insulating board, reducing the module's volume and increasing power density.
Implementation Method 1
a transformer, including a magnetic core and a winding wound on the magnetic core, the winding including a first winding and a second winding, the first winding being electrically connected to the first power device, and the second winding being electrically connected to the second power device
Data Source
Figure 1
Figure 2~3
Figure 4~5
AI summary
The present application provides a power module, including a first side plate (101), a second side plate (102), and an insulating board (100). The insulating board includes a flat plate portion (110), at least one protrusion portion (120), and at least one connecting bridge (130), the flat plate portion is parallel to a plane formed by a first direction (X) and a second direction (Y); at least one of the protrusion portion and the connecting bridge protrudes along a third direction (Z) to form an insulation cavity (140); the insulating board, the first side plate, and the second side plate in combination form a first accommodating space (11) and a second accommodating space (12) along the third direction, the first accommodating space is provided with a first power device (13), and the second accommodating space is provided with a second power device (14); and a transformer (200), including a magnetic core (210) and a winding wound on the magnetic core, the winding includes a first winding (220) and a second winding (230), at least part of the magnetic core is set within the insulation cavity or the connecting bridge; the first winding is electrically connected to the first power device, and the second winding is electrically connected to the second power device. The flat plate portion in the present application does not penetrate through an air gap of the magnetic core, which facilitates a control of a size of the air gap of the magnetic core and is beneficial for improving an efficiency of the transformer in the power module.