Transformer Insulating Plate Geometry for Easier Power Module Assembly
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Solution Overview
Problem
Current power modules face challenges with high installation accuracy and large deformation of insulating plates, leading to increased weight, complex manufacturing, and high costs due to the need for precise buckling of transformer components.
Innovation Solution
A power module design featuring a transformer with a primary and secondary side magnetic core, power elements, and an insulating plate with adaptive buckling and bending parts, reducing the need for precise alignment and minimizing deformation, thus simplifying assembly and manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a straight horizontal insulating plate is used between the front-stage conversion unit, primary side unit and post-stage conversion unit, secondary side unit, then insulation is provided, but the plate deforms easily requiring increased thickness which results in large housing weight and complex manufacturing process
Solution Approach 1:
The insulating plate transitions from a straight horizontal design to a curved design with buckling parts and bending parts. The curvature allows the plate to achieve the required insulation distance while maintaining structural rigidity with reduced thickness, thereby reducing housing weight without compromising insulation reliability.
Solution Approach 2:
The insulating plate incorporates variable thickness parameters through buckling parts and bending parts. These geometric parameter changes allow the plate to provide adequate insulation distance in critical areas while maintaining overall structural integrity with reduced material usage, achieving weight reduction without sacrificing insulation performance.
2Reliability
If a straight horizontal insulating plate is used, then insulation is provided, but the plate deforms easily requiring increased thickness which results in thick insulating plate and high cost
Solution Approach 1:
The curved design with integrated buckling and bending parts eliminates the need for separate support structures or reinforcement elements. This geometric integration simplifies the manufacturing process by reducing the number of components and assembly steps while maintaining insulation reliability through optimized curvature geometry.
Solution Approach 2:
The insulating plate combines multiple functions into a single component: insulation, structural support, and deformation compensation. The buckling parts and bending parts integrate support functionality directly into the insulating plate, reducing the need for additional structural elements and simplifying manufacturing.
3Ease of manufacture
If the primary side unit and secondary side unit of the transformer are buckled with each other with a straight plane buckle surface, then assembly is provided, but the buckle area is small requiring high buckle accuracy of ±0.15 mm which is difficult to achieve
Solution Approach 1:
The buckle surface transitions from a straight plane to a curved surface with buckling parts and bending parts. This curvature increases the effective buckle area by distributing the contact surface across a three-dimensional arc, thereby reducing the required precision per unit area and making the ±0.15 mm tolerance achievable through standard manufacturing processes.
Solution Approach 2:
The buckle interface extends from a two-dimensional straight plane to a three-dimensional curved surface. This dimensional transformation increases the available buckle area by utilizing the third dimension (curvature radius), allowing for larger total contact area while reducing the stringency of precision requirements in any single location.
Data Source
AI summary
The present application discloses a power module, including: at least one transformer, each transformer including a primary side magnetic core and a secondary side magnetic core; a primary side power element, the primary side magnetic core and the primary side power element forming a primary side conversion unit; a secondary side power element, the secondary side magnetic core and the secondary side power element forming a secondary side conversion unit; and an insulating plate, disposed between the primary side conversion unit and the secondary side conversion unit, and including a first area, the first area being adaptively disposed between the primary side magnetic core and the secondary side magnetic core, and the first area having at least one buckling part and/or at least one bending part.