Converter Module Integrated Magnetic Core Design
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Solution Overview
Problem
Conventional converter modules for data centers face challenges with high power consumption, large volume, and low power density due to the use of multiple transformers, which result in inefficiencies and increased thermal resistance, especially when handling high frequency and heavy current outputs.
Innovation Solution
A converter module design that omits several cover plates of the magnetic core, featuring a magnetic core with a core column parallel to the system board and carrier board units with via holes, primary and secondary windings, and switches, allowing direct connection to the system board and reducing magnetic loss, thereby enhancing power density and system efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple transformers are used to handle low voltage and heavy current, then the power density can be increased, but the volume of the magnetic core increases and production efficiency decreases
Solution Approach 1:
The patent merges multiple separate transformers into a single integrated transformer structure. Multiple primary windings are wound around a common magnetic core with multiple core columns, eliminating the need for separate magnetic cores for each transformer. This consolidation maintains the required power handling capability while significantly reducing the total magnetic core volume and improving production efficiency.
2Power
If multiple transformers are used with separate air-gap control, then the power conversion can be achieved, but the manufacturing consistency deteriorates and production efficiency decreases
Solution Approach 1:
The patent combines multiple air-gaps into a single integrated air-gap structure within the common magnetic core. The air-gap is formed by a single gapping piece that simultaneously creates all required air-gaps at the junctions of multiple core columns. This unified approach ensures consistent air-gap dimensions across all transformers, dramatically improving manufacturing consistency and efficiency while maintaining the required power conversion capability.
3Reliability
If conventional transformer design with cover plates is used, then the magnetic core structure is complete, but the volume is large and power density is reduced
Solution Approach 1:
The patent extracts and eliminates the cover plates from the magnetic core structure. The design relies on the inherent structural integrity of the core columns and the air-gap piece to maintain magnetic circuit completeness without requiring additional cover plate components. This extraction reduces the overall module volume and improves power density while maintaining sufficient structural integrity for reliable operation.
4Power
If high switching frequency is used to satisfy greater power density, then the power density increases, but the efficiency decreases due to high frequency heavy current
Solution Approach 1:
The patent merges multiple transformers into a single integrated structure with a common magnetic core and unified air-gap control. This integration reduces the total number of switching operations required while maintaining the same power output, thereby reducing switching losses and improving efficiency at high switching frequencies. The consolidated design allows for better current distribution and reduced electromagnetic interference.
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 design significantly reduces the magnetic core's volume, decreases magnetic loss, and improves system efficiency by allowing direct heavy current connections and enhanced heat dissipation, addressing the inefficiencies of conventional modules.
Implementation Method 1
each of the carrier board units comprises at least one primary winding, at least one secondary winding... The at least one core column passes through the via hole of each of the carrier board units
Data Source
AI summary
A converter module includes: a system board; and an isolated rectifier unit connected with the system board via at least one pin, the isolated rectifier unit including: a system board; a circuit module; and an isolated rectifier unit arranged adjacent to the circuit module and connected with the system board; wherein the isolated rectifier unit includes: a magnetic core comprising at least one core column parallel to the system board and two cover plates provided at both ends of the core column; and multiple carrier board units provided between the two cover plates and perpendicular to the system board, wherein each of the carrier board units comprises at least one via hole, at least one primary winding, at least one secondary winding and at least one switch connected with the at least one secondary winding.