Integrated Resonant Transformer Module for Compact OBC Layout
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric vehicle on-board chargers (OBCs) are bulky due to separate transformers and inductors, increasing mounting complexity and space requirements on printed circuit boards.
Innovation Solution
A resonant inductor integrated transformer module where resonant inductors are integrated within the transformer, allowing for compact design, high efficiency, and improved heat management through magnetic shielding and close contact winding of copper wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the transformer and inductor are physically separated in the LLC converter, then the individual components can be manufactured and assembled separately, but the OBC becomes bulky and the mounting time on PCB increases
Solution Approach 1:
The patent integrates the resonant inductor directly into the transformer structure by winding the inductor wire around the transformer core along with the primary and secondary coils. This merging of previously separate components (transformer and resonant inductor) into a single integrated module reduces the overall volume and eliminates the need for separate mounting of these components on the PCB.
2Ease of operation
If the transformer and inductor are physically separated, then assembly flexibility is maintained, but the man hour for mounting them on PCB increases
Solution Approach 1:
By combining the resonant inductor and transformer into a single integrated module, the number of separate components to be mounted on the PCB is reduced. This significantly decreases the mounting time and assembly complexity, while the modular nature of the integrated module itself provides sufficient assembly flexibility.
3Area of stationary object
If resonant inductors are integrated within the transformer, then the space occupied is reduced and PCB design becomes easier, but the transformer structure becomes more complex
Solution Approach 1:
The resonant inductor is formed by winding the wire in a direction perpendicular to the plane of the primary and secondary coils, utilizing the third dimension (height/depth) of the transformer core. This dimensional approach allows the inductor to occupy space that would otherwise be unused, reducing PCB footprint without significantly complicating the winding process.
4Ease of manufacture
If conventional round wires are used for winding, then the winding process is simple, but the space utilization and contact degree between wound surfaces are lower
Solution Approach 1:
The patent employs square-shaped wires instead of conventional round wires for winding the primary, secondary, and resonant inductor coils. The square cross-section of the wire allows for tighter packing and better contact between adjacent windings, maximizing the use of available space within the transformer core window and improving thermal contact between layers.
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 integrated design reduces the size and weight of the OBC, enhances efficiency, and minimizes leakage current while maintaining high voltage and current capabilities, improving the overall performance and competitiveness of the charger.
Implementation Method 1
resonant inductors provided in a transformer itself, so that the resonant inductors have resonance with the capacitance in the transformer itself
Implementation Method 2
primary and secondary coils of a transformer and resonant inductors to be shielded by magnetic cores
Implementation Method 3
applying bonding layers to the outer surfaces of the insulating sheaths, in such a way as to allow wound surfaces thereof to be brought into close contact with one another, and fusing and joining the wound surfaces
Data Source
AI summary
Provided is a resonant inductor integrated transformer module including: a transformer; and a first resonant inductor and a second resonant inductor as spiral coils located on one side and the other side of the transformer designed to resonate with capacitance in the transformer, wherein the transformer includes: a flat primary coil; and a flat secondary coil adapted to generate an induced current by an electric current applied to the primary coil, whereby the primary coil is formed by winding a first square-shaped adhesion type covered conductive wire in the form of a coil in such a way as to form a first hollow portion at the central portion thereof and the secondary coil is formed by winding a second square-shaped adhesion type covered conductive wire in the form of a coil in such a way as to form a second hollow portion at the central portion thereof.