Integrated Magnetic Assembly for Power Supply Systems
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Solution Overview
Problem
Conventional power supply systems with multiple converters have high volume, weight, and cost due to independent magnetic cores and flux paths, leading to significant magnetic losses.
Innovation Solution
A magnetic assembly where multiple magnetic elements share magnetic cores and flux paths, with stacked first magnetic cores and a second magnetic core, reducing volume, weight, and cost while increasing power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent magnetic cores are used in parallel converters, then each converter can operate independently, but the overall volume and weight increase significantly
Solution Approach 1:
The patent merges multiple independent magnetic cores into a single integrated magnetic core structure that serves all parallel converters. The magnetic core includes multiple limbs arranged in parallel, with each limb providing a magnetic flux path for a corresponding converter, thereby combining multiple functions into one unified component while reducing total weight and volume.
Solution Approach 2:
The integrated magnetic core structure performs multiple functions simultaneously: it provides independent magnetic flux paths for each converter while sharing common structural support and magnetic properties. The yoke connects all limbs and enables the single core to serve multiple converters universally.
2Adaptability or versatility
If multiple independent magnetic cores are used in parallel converters, then each converter has its own magnetic flux path, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple magnetic core requirements into a single manufacturing process. The integrated magnetic core with multiple limbs is manufactured as one piece, eliminating the need to produce and assemble multiple separate cores, thereby reducing fabrication cost while maintaining independent magnetic flux paths through the structured limb arrangement.
3Ease of operation
If multiple independent magnetic cores are used in parallel converters, then each converter operates autonomously, but the power density decreases
Solution Approach 1:
The patent transitions from horizontal arrangement of multiple separate cores to a vertical multi-limb structure within a single core. This dimensional reorganization allows multiple independent magnetic flux paths to coexist in a compact space, increasing power density while preserving converter autonomy through the parallel limb configuration.
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 solution effectively reduces the volume and weight of magnetic elements, lowers manufacturing costs, and enhances power density by sharing magnetic core components and flux paths, thereby improving the efficiency and control of parallel-connected converters.
Implementation Method 1
The coil winding is wound around the magnetic core to form a closed magnetic flux path. Consequently, the magnetic element is produced.
Data Source
AI summary
A magnetic assembly includes plural first magnetic cores, plural coil windings and a second magnetic core. Each of the plural first magnetic cores includes plural legs and a first connection part. The first connection part is connected with first terminals of the plural legs. The first connection part of the first magnetic core at an upper position is located adjacent to second terminals of the plural legs of the adjacent first magnetic core at a lower position. Each coil winding is wound around at least one leg of the plural legs of the corresponding first magnetic core so as to form a magnetic element of the corresponding converter. The second magnetic core is stacked over the plural first magnetic cores. The second magnetic core is located adjacent to the second terminals of the legs of the topmost first magnetic core.