Flatwise-Wound Transformer Power Module Design
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Solution Overview
Problem
Existing power modules for low-voltage, high-current, and high-frequency applications face challenges with uneven current distribution and increased losses due to undesired connections in edgewise-wound and flatwise-wound transformers, necessitating a solution for improved efficiency and power density.
Innovation Solution
A power module design featuring a flatwise-wound transformer with switching units positioned on opposite sides of the winding pillar, reducing connection losses and enhancing heat dissipation, while maintaining high power density and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If edgewise-wound winding is used, then the transformer can be manufactured with PCB, but the winding occupies larger area and has uneven current distribution
Solution Approach 1:
The patent inverts the traditional edgewise-wound configuration by positioning the winding face parallel to the axial direction of the winding pillar (flatwise-wound). This inversion reduces the winding area occupation while maintaining PCB manufacturing capability, directly resolving the contradiction between ease of manufacture and area occupation.
2Volume of stationary object
If flatwise-wound winding is used, then space utilization is improved and transformer size is reduced, but connection losses increase due to wider copper foil
Solution Approach 1:
The patent positions the switching units on opposite sides of the winding pillar in three-dimensional space, changing the connection path from a planar layout to a spatial arrangement. This dimensional change allows the use of wider copper foil for compactness while maintaining short connection paths through vertical stacking, thereby reducing connection losses despite the flatwise-wound configuration.
3Temperature
If switching units are positioned away from the winding pillar, then heat dissipation is improved, but connection losses increase
Solution Approach 1:
The patent utilizes the vertical dimension by positioning switching units on opposite sides of the winding pillar in a stacked configuration. This spatial arrangement enables effective heat dissipation through separation from the hot winding area while maintaining short connection paths through the vertical stacking approach, simultaneously achieving both heat dissipation and low connection loss.
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 reduces winding and connecting losses by 32.2% and improves heat dissipation, achieving higher power density and efficiency compared to conventional power modules.
Implementation Method 1
The transformer includes a magnetic core and a flatwise-wound winding, and the flatwise-wound winding is wound around a winding pillar of the magnetic core
Data Source
AI summary
The present disclosure provides a power module including a transformer, a first switching unit and a second switching unit; the transformer includes a magnetic core and a flatwise-wound winding wound around a winding pillar of the magnetic core; the flatwise-wound winding includes a first winding, a first end of the first winding and the first switching unit are electrically connected and are located on the first side face of the winding pillar, projections of the first switching unit, the first end of the first winding, and the winding pillar on the first side face overlap each other; a second end of the first winding and the second switching unit are electrically connected and are located on the second side face of the winding pillar, projections of the second switching unit, the second end of the first winding, and the winding pillar on the second side face overlap each other.