Integrated Multi-Phase Magnetic Transformer for Core Loss Reduction
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Solution Overview
Problem
The existing multi-phase LLC conversion circuits face challenges with large volume and difficulty in reducing core loss due to independent assembly of magnetic components, which hinders miniaturization and efficiency.
Innovation Solution
A magnetic integrated device comprising a first magnetic core plate and N magnetic elements arranged in sequence with phase-different and direction-opposite excitation currents, integrated into an N-phase transformer to reduce volume and core loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic components are assembled in parallel with independent processing, then each phase operates independently, but the volume increases and configuration space needs to be increased
Solution Approach 1:
The patent merges N separate magnetic components into a single integrated magnetic component with a shared magnetic core. The magnetic core includes N magnetic core units arranged in sequence, where adjacent units share a common magnetic core plate. This integration reduces the total volume and eliminates the need for separate assemblies while maintaining independent phase operation through phase-different excitation currents.
Solution Approach 2:
The magnetic core is segmented into N magnetic core units, each corresponding to a separate phase. Each unit has its own winding and can be excited independently with phase-different currents, allowing independent operation while being physically integrated into a compact structure.
2Ease of manufacture
If magnetic components are assembled in parallel with independent processing, then assembly is straightforward, but core loss cannot be reduced due to independent operation of each phase
Solution Approach 1:
By combining multiple magnetic components into one integrated structure with a shared magnetic core, the patent enables magnetic coupling between phases. This allows the application of phase-different excitation currents that produce alternating magnetic fields, achieving magnetic cancellation effects that reduce core loss while maintaining manufacturing simplicity.
Solution Approach 2:
The patent changes the operational parameters by applying phase-different excitation currents to adjacent magnetic core units. This parameter change creates alternating magnetic fields that cancel each other out, reducing the net magnetic flux and thereby reducing core loss in the shared magnetic core plates.
3Volume of moving object
If N magnetic elements are integrated into an N-phase transformer, then volume and manufacturing cost are reduced, but the structure becomes more complex
Solution Approach 1:
The transformer is segmented into N modular magnetic core units that can be independently designed and manufactured, then assembled by stacking the units with shared magnetic core plates. This modular segmentation simplifies the manufacturing process and reduces structural complexity while achieving compact integration.
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 the volume and manufacturing cost of the transformer, improves power density, and enhances efficiency by achieving magnetic cancellation and reducing core loss in LLC conversion circuits.
Implementation Method 1
since the excitation currents of the N magnetic elements have phases different from each other by 120 degrees, and the excitation directions of adjacent magnetic elements among the N magnetic elements are opposite, the effect of magnetic cancellation can be achieved, the power loss of the first magnetic core can be reduced
Data Source
AI summary
Disclosed is a magnetic integrated device including a first magnetic core plate and N magnetic elements, one of which is connected to the first magnetic core plate. Excitation currents of the N magnetic elements have phases different from each other by 360/N degrees, and excitation directions of adjacent magnetic elements are opposite, wherein N is an integer greater than or equal to 2. Each magnetic element includes a first magnetic core including a first magnetic core body, a first magnetic column and two first side columns fixed on the same side of the first magnetic core body, and a combined winding including a secondary winding and a primary winding which are wound around the first magnetic column, wherein a extension direction of the first magnetic column is towards the first magnetic core plate. Therefore, the cost, power consumption and space volume are reduced, and the power density is improved.