Integrated Magnetics for Soft Switching Converters
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Solution Overview
Problem
Integrated magnetic components for switched mode power converters, such as soft switching and LLC resonant converters, face challenges in achieving high power density and efficiency while being cost-effective and easy to manufacture, due to the use of complex geometries and bobbins that increase costs, leakage losses, and thermal resistance.
Innovation Solution
An integrated magnetic component with an 8-shaped core structure using two E-cores or an E-core and I-core configuration, where windings are directly placed on the flanges of the magnetic cores without bobbins, allowing for simplified manufacturing and improved power density and efficiency by reducing thermal resistance and copper losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If bobbins are used to wind coils on magnetic cores, then the winding process is easier and more standardized, but the power density decreases, thermal resistance increases, and leakage inductance losses increase
Solution Approach 1:
The patent removes the bobbin from the magnetic core structure, extracting the unnecessary intermediate component that causes energy losses. The windings are placed directly on the magnetic core, eliminating the air gap and associated fringing fields that create leakage inductance losses and reduce power density.
Solution Approach 2:
The patent introduces a coating layer as an intermediary between the winding wire and magnetic core. This thin insulating coating prevents direct contact and potential short circuits while maintaining close proximity, thereby minimizing air gap effects and reducing leakage losses compared to traditional bobbin structures.
2Reliability
If complex geometries are used in integrated magnetic components, then the electrical performance can be optimized, but the manufacturing complexity and costs increase
Solution Approach 1:
The patent divides the magnetic component into standardized modular sections with simple geometries. By segmenting the design into basic shapes that are easy to manufacture, the overall system achieves optimized electrical performance through careful arrangement of these simple modules rather than through complex monolithic geometries.
Solution Approach 2:
The patent optimizes electrical performance by adjusting parameters such as winding arrangements, core dimensions, and material properties rather than relying on complex geometries. This allows achieving high reliability through parameter optimization while maintaining simple, manufacturable structures.
3Adaptability or versatility
If multiple discrete magnetic components are used in soft switching converters, then the design flexibility is maintained, but the size and costs increase
Solution Approach 1:
The patent combines multiple discrete magnetic components into a single integrated magnetic structure. This merging reduces the overall volume by eliminating air gaps between separate components and reducing the total amount of magnetic material required, while maintaining the functional flexibility of having multiple inductive elements through careful winding arrangements on the integrated core.
4Strength
If bobbins are used for winding, then the mechanical support is provided, but the power density decreases and thermal resistance increases
Solution Approach 1:
The patent removes the bobbin structure that acts as a thermal barrier between the windings and magnetic core. By eliminating this intermediate layer, thermal paths are improved and thermal resistance is reduced, allowing better heat dissipation from the windings to the core and ultimately to the surrounding environment.
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 results in a compact assembly with reduced copper losses and stray inductances, enhancing the transient characteristics and overall efficiency of the converter while simplifying the manufacturing process and reducing costs.
Implementation Method 1
two magnetic cores forming an 8-shaped core structure
Implementation Method 2
at least one of the first electric winding wires is wound on a flange of the E-core
Data Source
AI summary
In an integrated magnetic component for a switched mode power converter, comprising two magnetic cores forming an 8-shaped core structure and at least two first electric winding wires, wherein at least one magnetic core is an E-core, at least one of the first electric winding wires is wound on a flange of the E-core.