Integrated Resonant Transformer Module for Compact OBC PCBs
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Solution Overview
Problem
Conventional on-board chargers (OBCs) for electric vehicles have bulky transformers due to physically separated inductors and transformers, leading to increased mounting time and space requirements on printed circuit boards (PCBs).
Innovation Solution
A resonant inductor integrated transformer module where resonant inductors are spiral coils integrated within the transformer, connected to primary and secondary coils, and resonate with capacitance within the transformer, reducing space and enhancing efficiency.
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 optimized independently, but the overall device becomes bulky and requires more mounting time on the PCB
Solution Approach 1:
The patent merges the transformer and resonant inductor into a single integrated transformer module. The resonant inductor windings are wound around the same magnetic core as the transformer, combining two previously separate components into one unified structure. This integration directly reduces the overall device volume while maintaining the ability to optimize electromagnetic parameters through unified design of the windings and core.
2Ease of manufacture
If the transformer and inductor are physically separated, then each component can be manufactured independently, but the number of parts increases and PCB mounting time increases
Solution Approach 1:
The transformer and resonant inductor are combined into a single integrated module that functions as one assembly. This reduces the number of discrete parts from two separate components to one unified component, thereby reducing PCB mounting time and assembly complexity while maintaining manufacturability through standardized production processes for integrated magnetic components.
3Volume of moving object
If resonant inductors are integrated within the transformer, then the space occupied is reduced and PCB design becomes easier, but the structural complexity of the transformer increases
Solution Approach 1:
The resonant inductor windings are nested around the same magnetic core as the transformer windings, with both sets of windings sharing the common magnetic path. This nesting arrangement allows the resonant inductor to be embedded within the transformer structure, reducing the overall space occupied while managing structural complexity through a systematic winding arrangement that follows the magnetic core geometry.
4Temperature
If the transformer and resonant inductor are integrated, then heat emission efficiency improves, but the thermal management complexity may increase
Solution Approach 1:
The integration of the transformer and resonant inductor into a single module with shared magnetic core and proximity of windings creates favorable thermal conditions. The close coupling allows for unified thermal management where heat generated in both components can be dissipated through common thermal paths and mounting structures, improving overall heat emission efficiency while avoiding the need for separate thermal management systems for each component.
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, high-efficiency transformer module for OBCs with improved heat emission efficiency and reduced PCB size and part count, facilitating easier circuit design and assembly.
Implementation Method 1
resonant inductors as spiral coils located on one side and the other side of the transformer in such a way as to be connected to primary and secondary coils of the transformer and resonate with the capacitance in the transformer
Implementation Method 2
the LLC converter has a transformer for converting a high-frequency AC voltage into a higher voltage
Data Source
AI summary
The present disclosure relates to a resonant inductor integrated transformer module including: a transformer; and resonant inductors as spiral coils located on one side and the other side of the transformer in such a way as to be connected to primary and secondary coils of the transformer and resonate with the capacitance in the transformer.