Helical Coil Frame Inductor for High-Voltage Parasitic Control
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Solution Overview
Problem
Power conversion circuits, such as those using silicon carbide transistors, require inductive components that can operate reliably under high voltage gradients and frequencies while maintaining compactness and minimizing parasitic effects like arcing and dielectric breakdowns.
Innovation Solution
The design incorporates a toroidal core with a helical frame and coaxial helical coils, which can be modular and fabricated using advanced techniques like 3-D printing, along with an enclosure for cooling and EMI shielding, to support high-voltage and high-frequency operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional inductive components are used in high-voltage power conversion circuits, then they can provide basic inductive function, but they suffer from arcing, dielectric breakdowns, and unreliable operation under high voltage gradients and frequencies
Solution Approach 1:
The patent employs a toroidal core geometry with helical coils wound around it, creating curved and continuous magnetic paths. This curved configuration eliminates sharp edges and corners that would concentrate electric fields, thereby preventing arcing and dielectric breakdowns while maintaining reliable operation under high voltage conditions
Solution Approach 2:
The helical coils are nested around the toroidal core in a concentric arrangement, with multiple coils positioned at different radial distances. This nested configuration optimizes magnetic coupling and flux distribution, reducing parasitic effects and improving reliability without requiring additional spacing or insulation that would increase component size
2Reliability
If inductive components are designed to withstand high voltages and frequencies, then reliability improves, but the component size and complexity increase
Solution Approach 1:
The toroidal core's curved geometry naturally concentrates magnetic flux within a compact volume, eliminating the need for large air gaps or extended magnetic paths. This allows the component to withstand high voltages and frequencies while maintaining a compact size suitable for modern power conversion applications
Solution Approach 2:
The patent optimizes the helical coil winding parameters, including turn density, radial positioning, and pitch, to achieve optimal magnetic coupling and minimize parasitic effects. By carefully adjusting these geometric parameters, the component achieves high-voltage and high-frequency performance without increasing volume
3Volume of moving object
If compact designs are used to reduce component size, then space efficiency improves, but cooling effectiveness and parasitic effect management become more difficult
Solution Approach 1:
The toroidal core's curved surface provides continuous contact area for heat dissipation, and the helical coil arrangement ensures uniform thermal distribution. This geometry enables effective cooling in a compact volume by maximizing surface area to volume ratio while maintaining structural integrity
Solution Approach 2:
The toroidal core structure serves multiple functions simultaneously: it provides the magnetic path for inductive operation, acts as a thermal management component through its heat-dissipating geometry, and functions as mechanical support for the helical coils. This multi-functionality achieves compact design without compromising cooling effectiveness
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 enables inductive components to withstand high voltages and frequencies effectively, reducing unwanted parasitic effects and ensuring reliable operation with efficient cooling and compact design.
Implementation Method 1
inductive components such as transformers and various types of inductors
Implementation Method 2
a conduit disposed in the enclosure, surrounding the core, the helical frame and the first and second helical coils, and configured to circulate a cooling fluid
Data Source
AI summary
An apparatus includes a core and a helical frame coaxial with a segment of the core and having first and second major surfaces on opposite sides of the helical frame and each normal to a surface of the segment. At least one helical coil conforms to at least one of the first and second major surfaces. In some embodiments, the at least one helical coil may include first and second helical coils conforming to respective ones of the first and second major surfaces.