Integrated Magnetic Core Layout for Compact Multi-Transformer Power Stages
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Solution Overview
Problem
Existing integrated electromagnetic components lack the ability to efficiently integrate multiple transformers and inductors, limiting compactness and increasing costs.
Innovation Solution
An integrated electromagnetic component is designed with a single magnetic core that incorporates two transformers and two inductors, utilizing a magnetic core with specific loop configurations and winding arrangements to achieve compactness and reduce costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple transformers and inductors are integrated into a single magnetic core, then power density and space utilization are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges multiple electromagnetic components (two transformers T1 and T2, and two inductors L1 and L2) into a single integrated magnetic core. The magnetic core contains four distinct loops, with each loop carrying specific windings to form the required transformers and inductors. This consolidation achieves high power density by eliminating the need for separate magnetic cores for each component, while the modular loop structure manages the inherent complexity through systematic organization.
Solution Approach 2:
The single magnetic core serves multiple functions simultaneously by providing magnetic coupling for two transformers and two inductors. Each loop of the magnetic core is designed to support specific electromagnetic functions, with the first loop carrying primary and secondary windings for transformer T1, the second loop for transformer T2, and the third and fourth loops for inductors L1 and L2 respectively. This multi-functionality reduces the overall component count and improves space utilization.
2Volume of moving object
If multiple transformers and inductors are integrated into a single magnetic core, then compactness and space utilization are improved, but manufacturing precision requirements increase
Solution Approach 1:
The magnetic core is segmented into four distinct loops, with each loop independently designed to carry specific windings. The first loop carries primary winding (111, 112) and secondary winding (121, 122) for transformer T1; the second loop carries primary winding (211, 212) and secondary winding (221, 222) for transformer T2; the third loop carries winding (31) for inductor L1; and the fourth loop carries winding (41) for inductor L2. This segmentation allows for standardized manufacturing of each loop while maintaining overall integration, thereby managing manufacturing precision requirements.
Solution Approach 2:
The windings are nested around the magnetic core loops in a systematic manner, with multiple windings concentrated on specific loops. This nesting arrangement allows for compact integration of multiple electromagnetic components within the single magnetic core structure, reducing overall volume while maintaining functional independence of each component through proper spatial organization of windings.
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 enhances power density and reduces costs by integrating two transformers and two inductors within a single magnetic core, improving efficiency and space utilization.
Implementation Method 1
at least two first windings wound around the first loop to be magnetically coupled, outside the common portions; at least two second windings wound around the second loop to be magnetically coupled, outside the common portions
Data Source
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AI summary
The component (400) comprises: - a magnetic core (K) forming: • a first loop (402A) and a second loop (402B) having a common portion (404), • a third loop (502A) having a common portion (504A) with the first loop (402A) and/or the second loop (402B), and • a fourth loop (502B) having a common portion (504B) with the first loop (402A) and/or the second loop (402B); - at least two first windings (W1A, W2A, W3A) wound around the first loop (406A) to be magnetically coupled, outside the common portions (404, 504A, 504B); - at least two second windings (W1B, W2B, W3B) wound around the second loop (406B) to be magnetically coupled, outside the common portions (404, 504A, 504B); - a third winding (508A) wound around the third loop (502A), outside the common portions (404, 504A, 504B);and - a fourth winding (508B) wound around the fourth loop (502B), outside the common portions (404, 504A, 504B).;