Integrated Transformer-Capacitor Assembly for High-Frequency DC/DC Converters
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Solution Overview
Problem
Existing DC/DC voltage converters with transformers suffer from high material, weight, and volume outlay, as well as losses due to long connection links and the skin and proximity effect, particularly at high transmission frequencies.
Innovation Solution
A transformer design where the capacitor arrangement is integrated into the transformer unit, using short electrical connections such as flat parts or wires, and ceramic capacitors, allowing for a structurally smaller and more efficient configuration with minimized losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the capacitor arrangement is connected as a standalone component with long connection links, then the transformer can be manufactured separately, but losses due to skin and proximity effect increase at high transmission frequencies
Solution Approach 1:
The capacitor arrangement is integrated directly into the transformer unit, forming a combined structural unit. The capacitor is mounted on the transformer housing or core, and electrical connections are made through short connecting parts such as flat parts or wires, eliminating long connection links and reducing skin and proximity effect losses at high transmission frequencies
Solution Approach 2:
The capacitor arrangement is nested within the transformer structure by mounting it on the transformer housing or core. The capacitor and transformer form a compact integrated unit where the capacitor is positioned close to the winding terminals, minimizing connection length while maintaining separate component identities
2Ease of operation
If traditional connection methods with long connecting lines are used, then ease of assembly is improved, but material outlay and volume increase
Solution Approach 1:
The capacitor arrangement and transformer form a integrated structural unit with minimal connection material. Short connecting parts such as flat parts or wires are used instead of long connection links, significantly reducing the quantity of connection material required while maintaining ease of assembly through standardized mounting positions on the transformer housing
3Adaptability or versatility
If long connection links are used to connect capacitor and transformer, then flexibility in positioning is improved, but losses due to skin and proximity effect increase
Solution Approach 1:
The capacitor is positioned close to the transformer winding terminals through direct mounting on the transformer housing or core, forming a compact integrated unit. This integration minimizes connection length and reduces skin and proximity effect losses, while the standardized mounting positions maintain sufficient positioning flexibility for assembly variations
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
This design reduces losses at high transmission frequencies, enables smaller ceramic capacitors, and allows for shorter electrical connections between power modules and the transformer, resulting in a more compact and efficient DC/DC voltage converter.
Implementation Method 1
The AC voltage generated by the first bridge circuit 10 is transformed by a transformer 30 that has a predefined turns ratio n:1
Implementation Method 2
A capacitor 34 or a capacitor arrangement 34 is provided between the output terminal 11A of the power module 11M and the stray inductance 33. By using the capacitor 34 connected in series with the stray inductance, this stray inductance is able to be compensated
Implementation Method 3
losses due to long connection links and the skin and proximity effect, particularly at high transmission frequencies
Implementation Method 4
losses due to long connection links and the skin and proximity effect, particularly at high transmission frequencies
Data Source
AI summary
A transformer for a DC-DC converter, such as a resonant converter, is provided. The converter includes a transformer unit that includes at least one winding with a first winding connection and a second winding connection, and a capacitor assembly consisting of at least one capacitor with a first capacitor assembly connection and a second capacitor assembly connection. The capacitor assembly is arranged so as to lie against the transformer unit in order to form an assembly. The capacitor assembly connections are connected to the winding connections via one or more first connection parts in a specified manner with respect to the electric connections. The capacitor assembly connections and/or the winding connections are electrically connected to multiple second connection parts in a specified manner with respect to the electric connections for connecting to a first power module and a second power module.