Isolated DC-DC Power Module: Safe for Medical Use?

The Life-or-Death Math of Medical Isolation

Medical-grade isolation requires:

• 2× Means of Patient Protection (2MOOP) at 4000VAC/10s

• Patient leakage current <10μA

• Creepage distances ≥8mm (per IEC 60601-1 Ed.3.1)

Leading modules like RECOM’s RMD-30 (32×20.5×10.2mm) achieve this via:

• Triple-insulated wire Transformers with polyimide-silica hybrid encapsulation

• 6kV reinforced isolation barriers using ceramic-filled polymers

• Guard ring PCB layouts eliminating surface tracking

Shrinking Safeguards: Engineering Nano-Isolation

A. Material Innovations

• Ferroxcube 3F45 cores reduce Transformer size by 40% vs. ferrite

• AlN (aluminum nitride) substrates with 170 W/mK thermal conductivity

• Parylene HT® conformal coating (<0.1% moisture absorption)

B. Topology Breakthroughs

• Active clamp flyback (e.g., TDK’s CUS400M series) slashes size 60% vs. LLC resonant

• Monolithic isolators (Silicon Labs Si86xx) replace optocouplers in 1.5mm²

C. Testing Protocol

• 100% production HIPOT testing at 6kVDC

• Partial discharge <3pC at 1.5× working voltage

Critical Applications Where Isolation Saves Lives

• Ventilators: Murata’s MEJ1S0505SC (16.5×10.5×8mm) ensures <5μA leakage in oxygen sensors

• Surgical Robots: KUKA’s LBR Med uses Vicor’s VI Chip® modules (22×17×7mm) with 5kVDC isolation for force feedback systems

• Implantable Monitors: Abbott’s FreeStyle Libre 3 employs RECOM’s RP-1224 (11.6×6.1×4mm) achieving 4000VAC isolation in 0.3cm³

The Next Frontier: Smarter Protection

• Self-monitoring isolation: TI’s AMC3330 integrates fault detection (ISO 13849 PL e)

• GaN isolation: Efficient Power Conversion’s EPC23102 enables 5kV/ns CMTI in 3×5mm

• 3D printed barriers: Nano-dimension dielectric inks creating 0.1mm insulation layers

Selection Checklist for Medical Designs

1. Certification: EN 60601-1 3rd Ed + ANSI/AAMI ES60601-1

2. MOOP Rating: Verify 2× protection minimum

3. BF/CF Rating: Body-floating (BF) or cardiac-floating (CF) classification

4. EMC Performance: Must pass IEC 61000-4-8 (20A/m immunity)

When patient safety hangs in the balance, only rigorously engineered isolated DC-DC power modules deliver uncompromised protection.

Request Medical Compliance Dossier:sales@ferrtx.com