Asymmetric Quad-Core Transformer for Flux Balancing
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Solution Overview
Problem
Existing automotive vehicle power electronic components face challenges in efficiently managing high power levels, leading to excessive losses in printed circuit board (PCB) windings due to uneven flux density and current distribution, which results in increased ferrite utilization and core losses.
Innovation Solution
A magnetically integrated quad-core transformer system with asymmetric air gap distribution and uneven winding arrangements between diagonal legs, allowing for balanced flux density and reduced ferrite utilization by connecting primary and secondary windings in series and parallel configurations, thereby controlling magnetizing and leakage inductances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If symmetric air gap distribution is used in quad-core transformers, then manufacturing is simpler, but flux density becomes uneven across core legs
Solution Approach 1:
The patent applies asymmetry by intentionally creating non-uniform air gap distributions in the quad-core transformer. Specifically, different air gap widths are introduced at different core legs (e.g., wider gaps at outer legs, narrower gaps at inner legs) to compensate for flux density variations. This asymmetric design allows each core leg to achieve balanced flux density despite the non-uniform physical structure, resolving the contradiction between manufacturing simplicity and flux uniformity.
2Power
If ferrite material is increased to handle high power levels, then power handling capacity improves, but core losses increase
Solution Approach 1:
The patent changes the air gap width parameters at different core legs to optimize magnetic flux distribution. By adjusting these geometric parameters asymmetrically, the transformer achieves balanced flux density across all legs, allowing efficient operation at high power levels without requiring excessive ferrite material. This parameter optimization reduces magnetic saturation and minimizes core losses while maintaining high power handling capacity.
3Ease of manufacture
If uniform winding distribution is used, then manufacturing is easier, but current sharing between parallel windings becomes uneven
Solution Approach 1:
The patent applies asymmetry to winding distribution by creating non-uniform winding arrangements that correspond to the asymmetric air gap structure. Different numbers of windings or different winding densities are placed at different core legs to match the asymmetric flux distribution. This asymmetric winding configuration ensures balanced current sharing among parallel windings, resolving the contradiction between manufacturing ease and current sharing precision.
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 achieves a 30% reduction in ferrite utilization and enables efficient current sharing and loss optimization, integrating large leakage inductance without increasing core size, while maintaining balanced flux density across core legs.
Implementation Method 1
Power systems may include transformers that permit flow of current between various sources and loads
Implementation Method 2
A magnetically integrated quad-core transformer system with asymmetric air gap distribution and uneven winding arrangements between diagonal legs, allowing for balanced flux density and reduced ferrite utilization
Data Source
AI summary
A first transformer includes a first quad core with four first legs and first windings wound around each of the first legs such that a winding direction for diagonal ones of the first legs is same. A second transformer includes a second quad core with four second legs and second windings wound around each of the second legs such that a winding direction for diagonal ones of the second legs is same. The first four legs and second four legs are arranged adjacent to, but spaced away from, each other to define four gaps. The first windings and second windings are in parallel.