Composite Transformer With Distributed Gap for Stable High Current Output
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Solution Overview
Problem
Existing transformers, particularly those used in converters, face challenges in maintaining desired output voltages due to fluctuations in input voltage, and they often require multiple parts and large sizes, which reduce efficiency and maximize space usage.
Innovation Solution
A low profile high current composite transformer is developed, featuring two conductive windings surrounded by a soft magnetic composite with distributed gaps, providing a near linear saturation curve and allowing for efficient operation in various converter applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional separate parts construction (core, windings, holding structure) is used, then assembly flexibility is improved, but device complexity and air spaces increase leading to larger component sizes
Solution Approach 1:
The patent combines the magnetic core, windings, and holding structure into a single integrated transformer component. The composite magnetic core is molded as one piece with the windings embedded within it, eliminating the need for separate parts and complex assembly processes while maintaining manufacturing efficiency.
Solution Approach 2:
The patent uses a composite magnetic core made from magnetic powder mixed with a binder material. This composite structure allows the core to be molded into complex shapes that integrate multiple functions (magnetic path, structural support, winding holder) into a single component, reducing part count while maintaining ease of manufacture.
2Ease of manufacture
If traditional separate parts construction is used, then assembly flexibility is improved, but air spaces increase reducing efficiency and increasing component size
Solution Approach 1:
The integration of windings directly into the molded composite core eliminates air gaps between separate components. This continuous magnetic path reduces magnetic reluctance and energy losses, improving transformer efficiency while maintaining manufacturing simplicity.
Solution Approach 2:
The patent changes the physical state and distribution of magnetic material by using a composite powder-binder formulation that can be molded. This allows the magnetic material to fill spaces completely around the windings, eliminating air gaps and improving magnetic coupling efficiency.
3Manufacturing precision
If distributed gap composite magnetic core is used, then saturation curve linearity is improved, but manufacturing complexity increases
Solution Approach 1:
The patent introduces distributed gaps within the composite magnetic core by adjusting the formulation or molding process parameters. This creates a more linear saturation curve, improving precision of magnetic characteristics while the molding process itself keeps manufacturing relatively simple.
Solution Approach 2:
The composite nature of the magnetic core (magnetic powder in binder) allows for easy introduction of distributed gaps through formulation adjustments or molding techniques, achieving precise magnetic characteristics without significantly increasing manufacturing complexity.
4Volume of moving object
If compact design is used, then space utilization is improved, but heat dissipation becomes more difficult
Solution Approach 1:
The composite magnetic core has an inherently porous or granular structure due to the powder-binder composition. This internal porosity provides thermal pathways for heat dissipation while maintaining a compact external dimensions, allowing efficient heat transfer from the windings through the magnetic core.
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 composite transformer achieves superior efficiency and compact size, effectively maintaining output voltage stability across varying input voltages, and optimizing space utilization while reducing assembly complexity and costs.
Implementation Method 1
The soft magnetic composite with distributed gap provides for a near linear saturation curve
Implementation Method 2
A low profile high current composite transformer is disclosed. Some embodiments of the transformer include a first conductive winding having a first start lead, a first finish lead, a first plurality of winding turns, and a first hollow core; a second conductive winding having a second start lead, a second finish lead, a second plurality of turns, and a second hollow core; and a soft magnetic composite compressed surrounding the first and second windings
Data Source
AI summary
A low profile high current composite transformer is disclosed. Some embodiments of the transformer include a first conductive winding having a first start lead, a first finish lead, a first plurality of winding turns, and a first hollow core; a second conductive winding having a second start lead, a second finish lead, a second plurality of turns, and a second hollow core; and a soft magnetic composite compressed surrounding the first and second windings. The soft magnetic composite with distributed gap provides for a near linear saturation curve.