Planar Transformer Design for Efficient EV Charging
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Summary
Problems
Existing medium voltage AC to DC converters in electric vehicle charging stations face challenges such as high eddy current and AC losses, high voltage isolation requirements, parasitic resistances and capacitances, and cooling inefficiencies in transformers, which affect efficiency and reliability.
Innovation solutions
A planar transformer design using magnetic cores, printed circuit boards, ceramic insulation, and embedded cooling tubes, along with dual active bridge modules, to minimize losses and enhance isolation and cooling, while utilizing MOSFET transistors for efficient power transfer.
TRIZ Analysis
Specific contradictions:
General conflict description:
Principle concept:
If LITZ wire is used to reduce eddy current losses, then eddy current losses are reduced, but the insulation occupies a large percentage of the winding space and cost increases
Why choose this principle:
The patent replaces traditional LITZ wire construction with planar PCB-based windings. The PCB traces serve as conductors with inherent insulation from the substrate, eliminating the need for individual strand insulation while maintaining low eddy current losses through the planar geometry and controlled trace configurations.
Principle concept:
If LITZ wire is used to reduce eddy current losses, then eddy current losses are reduced, but the insulation occupies a large percentage of the winding space and cost increases
Why choose this principle:
The patent uses composite construction combining PCB substrate (insulating material) with copper traces (conductive material) to create an integrated winding structure. This composite approach provides both electrical functionality and insulation in a single component, reducing overall insulation space requirements compared to traditional LITZ wire assemblies.
Application Domain
Data Source
AI summary:
A planar transformer design using magnetic cores, printed circuit boards, ceramic insulation, and embedded cooling tubes, along with dual active bridge modules, to minimize losses and enhance isolation and cooling, while utilizing MOSFET transistors for efficient power transfer.
Abstract
A protective enclosure for electrical components includes potting material encasing the electrical components. A case covers the potting material. At least one clastic component extends over the case for applying a compressive load to the potting material.