Integrated Inductor Layout for Compact LLC Flux Balancing
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Solution Overview
Problem
Existing LLC resonant converters occupy a large volume due to the use of individual magnetic components as resonant inductors and a parallel inductor, which hinders size reduction and leads to interference between magnetic fluxes generated by different windings, causing imbalances in current flow and potential breakdowns in semi-conductive elements.
Innovation Solution
The design incorporates three windings (first, second, and third windings) wound around a single magnetic member with specific core configurations and connecting portions, allowing independent operation of resonant inductors and a parallel inductor, reducing size and magnetic flux interference, and utilizing magnetic coupling to cancel out common mode currents and fluxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If individual magnetic components are used for resonant inductors and parallel inductor, then the converter can operate reliably, but the volume becomes large
Solution Approach 1:
The patent combines multiple magnetic components (resonant inductors and parallel inductor) into a single integrated magnetic component with multiple windings. The first and second windings form resonant inductors while the third winding forms the parallel inductor, all sharing a common magnetic core. This merging reduces the overall volume occupied by magnetic components while maintaining their individual functional independence through magnetic coupling.
2Volume of moving object
If multiple windings are placed close together to reduce size, then volume decreases, but magnetic flux interference increases causing current imbalance
Solution Approach 1:
The patent converts the potentially harmful magnetic flux interference into a beneficial effect by designing the windings such that their magnetic fluxes cancel each other out. The first and second windings are arranged to generate opposing magnetic fluxes that neutralize common mode currents and reduce electromagnetic interference. This transforms the interference problem into a flux cancellation mechanism that improves overall system performance.
3Object-generated harmful factors
If magnetic flux cancellation is implemented, then common mode noise is suppressed, but the device complexity increases
Solution Approach 1:
The patent achieves multi-functionality within a single magnetic member structure that simultaneously provides: (1) resonant inductance through first and second windings, (2) parallel inductance through the third winding, and (3) common mode noise suppression through flux cancellation. The connecting portions of the magnetic core serve multiple purposes by providing magnetic paths for both resonant and parallel inductors while enabling flux cancellation. This universal design reduces device complexity compared to implementing these functions with separate components.
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 a compact LLC resonant converter with independent operation of resonant and parallel inductors, reducing size, balancing current flow, and suppressing common mode noise, thereby preventing potential breakdowns and maintaining stable operation.
Implementation Method 1
allowing formation of a magnetic flux circulating between the first core and the third core, a magnetic flux circulating between the second core and the third core, and a magnetic flux circulating between the first core and the second core
Implementation Method 2
a first winding wound around the first core; a second winding wound around the second core; and a third winding wound around the third core
Implementation Method 3
utilizing magnetic coupling to cancel out common mode currents and fluxes
Implementation Method 4
a direction of a magnetic flux generated in the third core by a current flowing through the first winding and a direction of a magnetic flux generated in the third core by a current flowing through the second winding being opposite to each other
Data Source
AI summary
An inductor includes a magnetic member comprising a first core, a second core, a third core, and a connecting portion connecting the first core, the second core and the third core; a first winding wound around the first core; a second winding wound around the second core; and a third winding wound around the third core and connected between the first winding and the second winding. A direction of a magnetic flux generated in the third core by a current flowing through the first winding and a direction of a magnetic flux generated in the third core by a current flowing through the second winding are opposite to each other.