Interleaved Transformer Assembly for Balanced Current Sharing
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Solution Overview
Problem
Conventional power supplies face inefficiencies in power conversion due to current imbalances among transformer windings, particularly in high-frequency operations, which are exacerbated by the increasing power demands of digital loads and the transition to 48V architecture in data centers.
Innovation Solution
Implementing a transformer assembly with interleaved windings and external circuit modifications, including split resonant capacitors and parallel series circuit paths, to achieve balanced current flow and reduce impedance mismatch.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional transformer windings are used with varying heights in the stack, then the transformer can be manufactured with simple structure, but current distribution among windings becomes unbalanced leading to increased copper losses
Solution Approach 1:
The transformer windings are segmented into multiple discrete layers (first winding layer, second winding layer, third winding layer) with equal heights, where each layer carries a portion of the total current. This segmentation ensures balanced current distribution across all windings, reducing copper losses while maintaining manufacturability through standardized layer construction.
Solution Approach 2:
The patent transitions from a vertical stacking arrangement (varying heights in the stack direction) to a layered arrangement where windings are distributed across multiple horizontal layers of equal height. This dimensional reorganization balances the current path lengths and impedances, achieving uniform current distribution without increasing manufacturing complexity.
2Power
If high-frequency operation is implemented to meet increasing power demands, then power delivery capability is improved, but current imbalances among windings are exacerbated leading to reduced efficiency
Solution Approach 1:
The winding structure is divided into multiple equal-height layers, each carrying a balanced portion of the high-frequency current. This segmentation ensures that impedance differences between windings are minimized, allowing high-frequency operation to proceed without exacerbating current imbalances, thus maintaining power conversion efficiency while delivering required power levels.
Solution Approach 2:
Each winding layer is designed with identical local properties (equal height, consistent material composition, uniform spacing) to ensure that the electrical characteristics are matched across all windings. This local uniformity prevents current imbalances during high-frequency operation, enabling the system to achieve both high power delivery and high efficiency.
3Loss of energy
If 48V architecture is adopted to reduce conduction losses at 12V bus, then overall system efficiency is improved, but the requirement for precise current balancing among transformer windings becomes more critical
Solution Approach 1:
The transformer windings are segmented into multiple equal-height layers, which inherently balances the current distribution across windings. This segmentation approach simplifies the manufacturing process by using standardized layer heights, thereby achieving precise current balancing without requiring excessive manufacturing precision while supporting the 48V architecture's efficiency requirements.
Solution Approach 2:
The patent changes the critical parameter from varying winding heights to equal winding heights across multiple layers. This parameter change simplifies the current balancing requirement, as equal heights ensure matched impedances and balanced current distribution, thereby reducing the need for high manufacturing precision while maintaining the efficiency benefits of 48V architecture.
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 configuration enhances power conversion efficiency by minimizing copper losses and improving current sharing among windings, thereby optimizing energy utilization in data center power supplies.
Implementation Method 1
a first winding magnetically coupled to a second winding via a core of magnetic permeable material disposed in the transformer assembly
Implementation Method 2
The first series circuit path can be configured to include a first resonant circuit, the first circuit component disposed in the first resonant circuit; the second series circuit path can be configured to include a second resonant circuit, the second circuit component disposed in the second resonant circuit
Data Source
AI summary
An apparatus such as a power converter includes a transformer assembly, a first series circuit path, and a second series circuit path. The transformer assembly includes multiple windings such as a first winding and a second winding. The first series circuit path includes a first circuit component disposed in series with a first winding of the multiple windings; the second series circuit path including a second circuit component disposed in series with a second winding of the multiple windings. The first series circuit path is connected in parallel with the second series circuit path.