Spliced Insulating Cabin for Power Module Assembly
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Solution Overview
Problem
Existing power modules with traditional epoxy resin insulation face challenges in achieving high power density and simplified installation due to limited space and difficulties in connecting components, especially with thin insulating cabins and complex shapes.
Innovation Solution
A power module with a cabin structure featuring a shielding structure that includes equipotentially connected conductor layers and a solid insulating layer, allowing for flexible bending or splicing to wrap around the circuit module, enhancing insulation and safety while simplifying assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional epoxy resin casting molding is used for insulating cabin, then insulation performance is achieved, but installation accuracy cannot be improved and assembly is complex
Solution Approach 1:
The insulating cabin is divided into multiple spliced sections that can be separately manufactured and then assembled together. This segmentation allows each section to be produced independently with standard molds, improving installation accuracy while maintaining insulation performance through the spliced structure.
Solution Approach 2:
Instead of casting the entire insulating cabin as a single piece, the patent inverts the approach by using spliced sections that are assembled to form the complete insulating structure. This reversal of the manufacturing methodology simplifies assembly while ensuring reliable insulation.
2Power
If insulating cabin thickness is reduced to improve power density, then power density increases, but manufacturing yield deteriorates
Solution Approach 1:
The thin insulating cabin is divided into multiple spliced sections, each with manageable thickness. This allows the overall cabin to achieve reduced thickness for high power density while each individual section can be manufactured with acceptable yield using standard casting processes.
Solution Approach 2:
The spliced insulating cabin structure enables the use of thinner insulating sections that can be flexibly assembled. This approach maintains adequate insulation performance while reducing overall thickness to improve power density, overcoming the manufacturing yield issues associated with casting extremely thin single-piece cabins.
3Ease of manufacture
If preformed insulating cabin with limited space is used, then manufacturing is simplified, but installation accuracy cannot be improved
Solution Approach 1:
The insulating cabin is segmented into multiple sections that are spliced together. Each section can be manufactured with standard precision using simplified processes, while the splicing mechanism enables high installation accuracy through precise positioning and connection of the sections.
4Device complexity
If traditional casting process is used for thin insulating cabin, then manufacturing process is simple, but manufacturing yield deteriorates
Solution Approach 1:
The thin insulating cabin is divided into multiple sections that can each be manufactured with acceptable yield using simple casting processes. The segmented approach allows standard mold casting to be applied to manageable thicknesses while the overall thin-cabin goal is achieved through splicing.
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
The solution provides improved insulation performance, increased safety, and easier assembly by allowing the cabin to be fixed externally after the circuit module is assembled, reducing manufacturing complexity and cost.
Implementation Method 1
a solid insulating layer, provided between the first conductor layer and the second conductor layer and configured to electrically isolate the first conductor layer and the second conductor layer
Implementation Method 2
a first conductor layer, the first conductor layer being located at a side close to the circuit module and equipotentially connected to the circuit module
Data Source
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AI summary
The present invention provides a power module and a solid-state transformer system. The power module includes: a circuit module, having a voltage level; and a cabin, configured to wrap the circuit module by bending or splicing, where the cabin has a shielding structure, the shielding structure including: a first conductor layer, located at a side close to the circuit module and equipotentially connected to the circuit module; a second conductor layer, arranged apart from the first conductor layer and located at a side away from the circuit module; and a solid insulating layer, provided between the first conductor layer and the second conductor layer for electrically isolating the first conductor layer and the second conductor layer. The power module provided by the present invention has good insulation performance and is easy to assemble.