Fractional-Turn Transformer Core Layout for Higher Power Density
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Solution Overview
Problem
Current power supply units for communications devices face challenges in increasing power density due to high winding losses and inefficient magnetic core structures, which restrict size reduction and increase costs.
Innovation Solution
A transformer design with a magnetic core structure that allows both primary and secondary windings to be wound around interconnected magnetic cylinders, utilizing an annular configuration to reduce winding losses and improve magnetic flux coupling, thereby enhancing power density and reducing product costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If switching frequency is increased to reduce power magnetic element volume, then power density is improved, but winding loss increases
Solution Approach 1:
The patent transitions from traditional linear winding arrangements to a planar winding structure where windings are arranged in layers on a flat magnetic core. This dimensional change allows for shorter terminal lengths and reduced high-frequency effects, thereby reducing winding loss while maintaining high power density at MHz switching frequencies
Solution Approach 2:
The patent employs an annular magnetic core structure with curved windings that follow the circular path. This curvature optimizes the magnetic flux distribution and reduces leakage inductance, improving coupling between primary and secondary windings while minimizing winding loss at high frequencies
2Loss of energy
If fractional turn is used to reduce winding loss, then winding loss is reduced, but magnetic core window utilization becomes inefficient
Solution Approach 1:
The planar winding structure allows windings to be arranged in multiple layers across the magnetic core window, maximizing space utilization. The fractional turn design is integrated into this planar layout, enabling efficient use of the magnetic core window area while maintaining reduced winding loss benefits
3Reliability
If primary and secondary windings are wound on different magnetic cylinders, then coupling is improved, but leakage inductance increases
Solution Approach 1:
The patent implements nested windings where primary and secondary windings are interleaved in layers on the same magnetic core. This nesting arrangement ensures that turns from both windings are closely coupled, minimizing leakage inductance while maintaining strong magnetic coupling between primary and secondary sides
4Reliability
If terminal length is increased for safety spacing, then insulation is improved, but high-frequency loss increases
Solution Approach 1:
The patent employs planar winding structures with integrated insulation layers and magnetic core covers that provide safety spacing without requiring long terminal extensions. The thin film insulation layers and compact planar layout maintain adequate insulation distances while minimizing terminal length and associated high-frequency losses
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 design effectively reduces winding losses, improves magnetic flux utilization, and increases power density, leading to more compact and cost-effective power supply units for communications devices.
Implementation Method 1
When the primary-side switch circuit supplies power to the primary-side winding, a magnetic flux is generated around the primary-side winding on the first magnetic cylinder and the second magnetic cylinder
Implementation Method 2
A secondary-side winding is separately wound around the first magnetic cylinder and the second magnetic cylinder, the secondary-side winding is configured to induce the magnetic flux on the first magnetic cylinder or the second magnetic cylinder to generate a current
Data Source
AI summary
This application relates to the field of electronic technologies, and discloses a transformer and a power supply, to provide a magnetic cylinder distribution structure of a magnetic core while reducing a winding loss by using fractional turn, where the magnetic cylinder distribution structure of the magnetic core is conveniently to implement, thereby reducing product costs. The transformer includes a magnetic core, where the magnetic core includes a first magnetic cylinder and a second magnetic cylinder. One end of the first magnetic cylinder is coupled to one end of the second magnetic cylinder and the other end of the first magnetic cylinder is coupled to the other end of the second magnetic cylinder, to form an annulus.