Integrated Magnetic Core Layout for LLC Imbalance Compensation
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Solution Overview
Problem
Conventional integrated magnetic components for LLC resonant converters face challenges such as high weight, volume, and cost, as well as inadequate compensation for current imbalances and magnetic flux imbalances, particularly in three-phase converters.
Innovation Solution
The integration of at least one first type magnetic core element with three legs and at least one second type magnetic core element with five legs, stacked such that their legs are arranged in a row, allows for a reduced weight and volume while effectively compensating for current and magnetic flux imbalances through the differing number of legs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional stacked E-core arrangements are used, then the magnetic component can be assembled, but it cannot adequately compensate for current imbalances and magnetic flux imbalances in three-phase converters
Solution Approach 1:
The patent employs asymmetric magnetic core arrangements where E-cores and W-cores are stacked in non-uniform configurations. Specifically, the W-cores have different leg arrangements compared to conventional symmetric E-core stacks, creating asymmetric magnetic paths that naturally compensate for current imbalances and magnetic flux imbalances in three-phase converters.
Solution Approach 2:
The magnetic component is segmented into distinct E-core and W-core elements that can be independently configured. This segmentation allows each core type to serve specific functions: E-cores for certain phase connections and W-cores for others, enabling tailored compensation for three-phase current imbalances while maintaining modularity for easier assembly.
2Reliability
If stacked W-core arrangements are used for three-phase converters, then current and magnetic flux imbalances can be compensated, but high amounts of expensive magnetic material and high volume and weight are necessary
Solution Approach 1:
The patent merges E-cores and W-cores into a single integrated magnetic component structure. By combining the advantages of both core types in one stacked assembly, the design achieves effective current and flux balance compensation while reducing the total magnetic material required compared to using W-cores alone, thereby lowering weight and cost.
Solution Approach 2:
Different sections of the magnetic component use different core types (E-cores versus W-cores) optimized for local requirements. This local differentiation ensures that magnetic material is strategically placed only where needed for compensation, avoiding unnecessary material usage and reducing overall weight while maintaining compensation effectiveness.
3Ease of manufacture
If conventional magnetic components are used, then assembly is possible, but the components have high volume and are not cost-effective
Solution Approach 1:
The patent optimizes the stacking arrangement of E-cores and W-cores to improve space utilization in three-dimensional space. By carefully arranging cores along the stacking direction and optimizing their relative positions, the design reduces unused space and achieves more compact volume while maintaining assembly simplicity through standardized stacking interfaces.
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 results in a more efficient and cost-effective LLC resonant converter with improved thermal and electric efficiency, reduced losses, and lower weight, volume, and cost.
Implementation Method 1
the return legs, around which no winding is wound, together with the yoke close a magnetic circuit generated by a magnetic flux by the windings of the winding legs
Data Source
AI summary
The present disclosure concerns an integrated magnetic component for a converter, comprising: at least one first type magnetic core element comprising a yoke and at least three legs, wherein a first total number of legs is defined as a number of the legs of each of the at least one first type magnetic core element; at least one second type magnetic core element comprising a yoke and at least three legs wherein a second total number of legs is defined as a number of the legs of each of the at least one second type magnetic core element; and the first total number of legs (5, 6) and the second total number of legs (5, 6) are non-equal. The present disclosure also concerns a unidirectional LLC resonant converter and a bidirectional LLC resonant converter.