Integrated Magnetic Core Structure for High-Power Inductor-Transformer
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Solution Overview
Problem
Magnetic devices in high-power applications face challenges with volume, weight, and loss due to the need for customized core designs, which complicates product development and manufacturing.
Innovation Solution
A magnetic device with a core structure featuring a first and second magnetic cover, multiple winding columns, and a common side column, where the winding columns are configured to integrate inductor and transformer functions, allowing for efficient power handling and reduced size, suitable for low-voltage high-current applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If customized core design is used for high power supply, then power handling capability is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The magnetic core structure integrates both inductor and transformer functions within a single unified design. The core includes winding columns that can accommodate both inductor windings and transformer windings (primary and secondary), allowing one core structure to perform multiple functions that traditionally required separate components. This multi-functionality maintains high power handling capability while reducing design complexity and standardizing the core structure.
2Power
If customized core design is used for high power supply, then power handling capability is improved, but manufacturing cost and difficulty increase
Solution Approach 1:
The standardized core structure with integrated inductor and transformer columns enables a single manufacturing process to produce cores suitable for both inductor and transformer applications. This universality allows manufacturers to use the same tooling, assembly procedures, and quality control processes for different power products, significantly reducing manufacturing complexity and cost while maintaining high power capability.
3Adaptability or versatility
If traditional separate inductor and transformer components are used, then design flexibility is maintained, but device volume and weight increase
Solution Approach 1:
The patent combines separate inductor and transformer components into a single integrated magnetic core structure. The core includes distinct winding columns for inductors and transformers that share common magnetic paths and structural support. This merging reduces the overall device volume and weight by eliminating redundant magnetic cores, mounting structures, and insulation materials that would be required if separate components were used.
4Adaptability or versatility
If traditional separate inductor and transformer components are used, then design flexibility is maintained, but weight increases
Solution Approach 1:
The integrated core structure combines multiple magnetic components into a single unified structure, eliminating the weight of separate cores, mounting hardware, and inter-component insulation. The shared magnetic paths and common structural elements reduce the total amount of magnetic material required while maintaining the electrical isolation and functional independence needed for both inductor and transformer operations.
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 enables high-efficiency, low-cost magnetic devices with reduced core volume and losses, facilitating easier power spreading and heat dissipation while maintaining a constant number of PCB layers.
Implementation Method 1
the magnetic flux directions on adjacent transformer columns are opposite to each other when providing a current in the corresponding primary windings simultaneously
Data Source
AI summary
A magnetic dev ice includes a core structure, at least one inductor winding and at least two transformer windings. The core structure includes at least one inductor column and at least two transformer columns. The at least one inductor winding respectively winds around the at least one inductor column. The at least two transformer windings, wind around the at least two transformer columns respectively, and the transformer winding includes primary winding and secondary winding. Wherein the magnetic flax directions on adjacent transformer columns are opposite to each other when providing a current in the corresponding primary windings simultaneously.