Three-Board Rectifier Module Layout for Lower Output Ripple
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional rectifier modules have limited space for mounting filtering elements, resulting in unsatisfactory dynamic response and poor output ripple characteristics due to the arrangement of components on two circuit boards surrounding a transformer.
Innovation Solution
A rectifier module design with three circuit boards, including a transformer between two main circuit boards and an additional circuit board adjacent to the transformer, allowing for increased space for output filter capacitors, improved heat dissipation, and optimized filtering through a CLC filtering circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If filtering elements are disposed on the circuit boards on both sides of the transformer, then the rectifier module structure is compact, but the available space for mounting filtering elements is limited
Solution Approach 1:
The patent transitions from a two-dimensional planar arrangement of filter capacitors on circuit boards to a three-dimensional configuration by introducing a dedicated filter capacitor board positioned adjacent to the transformer. This vertical/dimensional expansion allows multiple filter capacitors to be mounted in stacked or adjacent positions, significantly increasing the number of capacitors without proportionally increasing the footprint area on the main circuit boards.
Solution Approach 2:
The patent separates the filter capacitor mounting function from the main circuit boards by introducing a dedicated filter capacitor board. This segmentation allows the filtering function to be independently optimized with specialized mounting space, while the main circuit boards focus on their primary functions. The filter capacitor board acts as an independent module that can accommodate multiple capacitors without interfering with the main circuit layout.
2Reliability
If more filtering elements are added to improve dynamic response, then the output ripple characteristics improve, but the device complexity increases
Solution Approach 1:
The patent combines multiple filter capacitors onto a single dedicated filter capacitor board, merging their mounting functions into one standardized platform. This consolidation allows multiple capacitors to be installed using uniform mounting procedures, reducing the overall assembly complexity compared to distributing individual capacitors across multiple circuit boards. The unified board structure simplifies both installation and maintenance operations.
3Speed
If the rectifier module uses a conventional two-circuit-board structure, then the structure is simple, but the dynamic response characteristics are unsatisfactory
Solution Approach 1:
The patent adds a third dimension to the conventional two-circuit-board structure by introducing a filter capacitor board positioned adjacent to the transformer in the vertical or lateral direction. This dimensional expansion enables the placement of multiple filter capacitors closer to the transformer, reducing the electrical path length and improving the dynamic response characteristics without significantly complicating the overall structural arrangement.
Data Source
AI summary
A rectifier module is disposed on a mainboard. The rectifier module includes a first circuit board, a second circuit board, a transformer, a third circuit board and a plurality of output filter capacitors. The first circuit board and the second circuit board are inserted into the mainboard. The first circuit board and the second circuit board are opposite to each other. The transformer is arranged between and connected to the first circuit board and the second circuit board. A first side of the third circuit board is connected to the first circuit board. A second side of the third circuit board is connected to the second circuit board. The plurality of output filter capacitors are disposed on the third circuit board. The rectifier module is electrically connected to the mainboard via a positive connection part and a negative connection part.