Bobbin-less U/UR Core Magnetic Component Design
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Solution Overview
Problem
Current integrated magnetic structures for switched mode power converters face challenges in reducing costs, improving efficiency, and enhancing power density due to the use of complex core structures, bobbins, and air gaps, which lead to increased thermal resistance and leakage losses.
Innovation Solution
The magnetic component utilizes bobbin-less U/UR cores assembled in a flexible manner with windings directly on the cores, allowing for adjustable air gaps to optimize magnetic properties, reducing the need for bobbins and enhancing core coupling, thereby minimizing leakage and thermal resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bobbins are used to wind the windings on the core, then the winding process is easier and more standardized, but the device complexity increases and power density decreases due to the additional component occupying space
Solution Approach 1:
The patent removes the bobbin from the magnetic component structure entirely. The windings are applied directly to the core segments without any bobbin support structure, eliminating an unnecessary component that added complexity and reduced power density while maintaining manufacturability through direct winding techniques
Solution Approach 2:
Instead of winding wire around a bobbin and then attaching the bobbin to the core, the patent inverts the traditional approach by winding the wire directly onto the core segments themselves, making the core the direct support structure for the windings rather than an indirect attachment via bobbin
2Adaptability or versatility
If air gaps are introduced to adjust magnetizing inductance, then the magnetic properties can be optimized, but the thermal resistance increases and efficiency decreases
Solution Approach 1:
The patent introduces air gaps only at specific locations where magnetic property adjustment is needed, rather than uniformly throughout the structure. The air gaps are strategically positioned to optimize magnetizing inductance while minimizing their impact on thermal pathways, allowing localized magnetic optimization without compromising overall thermal performance
Solution Approach 2:
The patent adjusts the size, position, and distribution of air gaps as design parameters to optimize magnetic properties. By carefully controlling the air gap dimensions and locations, the magnetizing inductance can be tuned to desired values while managing the trade-off with thermal resistance through parameter optimization
3Adaptability or versatility
If multiple discrete magnetic components are used, then the design flexibility is higher, but the size and costs increase
Solution Approach 1:
The patent merges multiple discrete magnetic components (transformer and inductors) into a single integrated magnetic structure with shared core segments. This consolidation reduces the overall volume and component count while maintaining the functional flexibility of having separate transformer and inductor windings on the same magnetic path
Solution Approach 2:
The patent creates a universal magnetic component structure where the same core segments can serve multiple functions - acting as both transformer cores and inductor cores depending on how windings are applied. This multi-functional design allows a single component to replace what would traditionally require multiple discrete components, reducing size while preserving design flexibility
4Adaptability or versatility
If the number of windings and interconnections is increased, then the functionality is enhanced, but the winding losses and interconnection losses increase
Solution Approach 1:
The patent merges multiple windings onto shared core segments, allowing multiple windings to utilize the same magnetic path efficiently. This reduces the total amount of copper required compared to separate discrete components, lowering winding losses while maintaining the functionality of multiple windings for different circuit requirements
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
This configuration results in reduced costs, improved power density, lower losses, and enhanced efficiency by eliminating bobbins and optimizing magnetic flux paths, while maintaining mechanical stability through distributed air gaps.
Implementation Method 1
at least one winding wound directly on the first, the second, and/or the third U/UR core
Implementation Method 2
a first and a second U/UR core assembled to a first O-shaped core assembly
Data Source
Figure 1~2
Figure 3a
Figure 3b
AI summary
A magnetic component, with a first and a second U/UR core (U1,U2) assembled to a first O-shaped core assembly, wherein an U/UR core has - according to its shape - a first post and a second post with free ends on one side and a leg connecting the first post and the second post on their other side, wherein the first and the second U/UR core (U1,U2) are assembled with their free ends abutting each other to form the first O-shaped core assembly. A third U/UR core (U3) is abutting the outside of the first O-shaped core assembly. At least one winding is wound directly on the first, the second and/or the third U/UR core (U1,U2, U3). The core structure can either be fully composed of high permeability low saturation cores with air gaps or be composite comprising low permeability high saturation cores and high permeability low saturation cores with no air gaps.