Integrated Magnetic Core Assembly for High-Density Power Modules
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Solution Overview
Problem
Conventional power modules with multiple magnetic cores for increased output power suffer from high fabrication costs and large volume, which hinders miniaturization and reduces power density due to the need for multiple converter circuits and magnetic cores.
Innovation Solution
A magnetic assembly with a single magnetic core and four windings per phase, where primary and secondary windings are magnetically coupled, forming four transformers with specific phase differences, allowing for magnetic integration and reduced volume, and a power module design with two phase conversion circuits sharing a magnetic core to enhance power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple magnetic cores are used to increase output power, then the output power is improved, but the fabrication cost increases and the volume increases
Solution Approach 1:
The patent merges multiple magnetic cores into a single integrated magnetic core structure. The first and second magnetic cores are combined into one magnetic core with multiple legs, where the first primary winding and second primary winding are wound on different legs of the same magnetic core. This integration reduces the number of separate magnetic cores needed, thereby lowering fabrication cost while maintaining the required output power through magnetic coupling between the windings on different legs.
Solution Approach 2:
The single magnetic core serves multiple functions simultaneously. It provides magnetic coupling for both the first primary winding and second primary winding, supports both first secondary winding and second secondary winding, and enables both phase conversion circuits to operate. This multi-functionality eliminates the need for separate dedicated magnetic cores for each winding pair, reducing overall device complexity and cost.
2Power
If multiple magnetic cores are used to increase output power, then the output power is improved, but the volume increases which hinders miniaturization
Solution Approach 1:
The patent combines multiple magnetic cores into a single integrated magnetic core structure that occupies less space than multiple separate cores. The magnetic core has a compact structure with multiple legs arranged in a confined space, allowing the first and second primary windings and first and second secondary windings to be wound on different legs while maintaining close magnetic coupling. This integration significantly reduces the overall volume of the power module.
Solution Approach 2:
The windings are nested on the legs of the magnetic core in a space-efficient manner. The primary windings and secondary windings are wound on different legs of the same magnetic core, with each winding occupying its own leg space. This nesting arrangement allows multiple windings to coexist in a compact configuration, minimizing the volume required for the transformer assembly while maintaining electrical isolation and magnetic coupling.
3Power
If multiple magnetic cores are used to increase output power, then the output power is improved, but the power density decreases due to increased volume
Solution Approach 1:
The patent integrates multiple magnetic cores into a single magnetic core structure, which concentrates the magnetic flux and windings into a smaller volume. This merging increases the power density by maintaining high output power while reducing the space occupied by the magnetic assembly. The magnetic core efficiently channels magnetic flux through its legs, maximizing the power output per unit volume.
Solution Approach 2:
The patent changes the magnetic circuit parameters by using a single magnetic core with multiple legs instead of multiple separate cores. This parameter change allows for optimized magnetic flux distribution and reduced magnetic path length, improving the efficiency and power density of the transformer. The phase difference control (150-210 degrees between adjacent legs) optimizes the magnetic coupling parameters to maximize power transfer density.
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 reduces fabrication costs, minimizes volume, and increases power density by utilizing a single magnetic core for two phase conversion circuits, allowing for more components on the circuit board and reduced power loss.
Implementation Method 1
Each of the four primary windings and the corresponding secondary winding of the four secondary windings are magnetically coupled with each other and wound on the corresponding lateral leg of the four lateral legs
Implementation Method 2
A phase difference between a magnetic flux flowing through a specified lateral leg of the four lateral legs and a magnetic flux flowing through an adjacent lateral leg is any value in the range between 150 degrees and 210 degrees
Data Source
AI summary
A magnetic assembly includes a magnetic core, four primary windings and four secondary windings. The magnetic core includes four lateral legs. The four primary windings and the corresponding secondary windings are magnetically coupled with each other, and the four primary windings and the corresponding secondary windings are wound on the corresponding lateral legs. The winding directions of the four secondary windings on the corresponding lateral legs are identical. A phase difference between a magnetic flux flowing through a specified lateral leg of the four lateral legs and a magnetic flux flowing through an adjacent lateral leg is any value in the range between 150 degrees and 210 degrees. A phase difference between the magnetic flux flowing through the specified lateral leg and the magnetic flux flowing through another adjacent lateral leg is any value in the range between 60 degrees and 120 degrees.