Integrated Transformer Merging PFC Inductor and Coil
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Solution Overview
Problem
The existing power supply devices employing switching mode power supplies (SMPS) face challenges in minimizing volume and improving productivity due to the separate configurations of Power Factor Correction (PFC) circuits and transformers, leading to increased size and reduced interaction efficiency between these components.
Innovation Solution
An integrated-type transformer is designed, where the PFC circuit and transformer are configured as a single component, utilizing a linear-type magnetic member, bobbin, and winding parts to integrate the inductor and coils, minimizing volume and improving productivity by reducing oscillating phenomena through synchronized operating frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the PFC circuit and transformer are configured in mutually different structures, then the interaction between components is effectively reduced, but the volume of the power supply device increases
Solution Approach 1:
The patent combines the PFC circuit inductor and transformer into a single integrated component structure. The inductor and transformer share a common magnetic core and winding structure, allowing both functions to be performed by one component rather than two separate components, thereby reducing overall volume while maintaining functional performance
Solution Approach 2:
The integrated component serves multiple functions simultaneously - it acts as both the PFC inductor and the transformer. The winding structure is designed to provide both the inductance required for power factor correction and the voltage transformation capability, making a single component perform the roles of what would traditionally require two separate components
2Ease of manufacture
If the PFC circuit and transformer are configured in mutually different structures, then the components can be manufactured independently, but the productivity of the power supply device decreases
Solution Approach 1:
The patent integrates the PFC inductor and transformer into a single manufacturable unit with a unified magnetic core and winding structure. This integration allows for streamlined manufacturing processes where both functions are produced simultaneously in one assembly operation, improving productivity by eliminating the need for separate manufacturing and assembly steps for two distinct components
3Adaptability or versatility
If the operating frequency of the transformer is not synchronized with the PFC circuit, then the transformer can operate independently, but oscillating phenomena occur reducing circuit reliability
Solution Approach 1:
The patent implements dynamic frequency synchronization between the transformer and PFC circuit operations. The system is designed to operate at a common switching frequency that coordinates both functions, allowing the integrated component to adapt its operational parameters to maintain synchronization and prevent oscillating phenomena that would occur with independent frequency operations
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-type transformer minimizes volume, enhances productivity, and ensures circuit reliability by integrating the PFC circuit and transformer, reducing interference and oscillations by aligning the transformer's operating frequency with the PFC circuit's frequency.
Implementation Method 1
a power factor correction circuit disposed to a left of the linear-type magnetic member and including an inductor; and a transformer disposed to a right of the linear-type magnetic member and including a primary coil and a secondary coil
Data Source
AI summary
An integrated-type transformer according to an embodiment includes a linear-type magnetic member; a power factor correction circuit disposed to a left of the linear-type magnetic member and including an inductor; and a transformer disposed to a right of the linear-type magnetic member and including a primary coil and a secondary coil.