Interleaved Transformer With Three-Core Magnetic Structure
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Solution Overview
Problem
Existing structured transformers coupled with inductor flux face issues such as magnetic saturation, noise/ripple voltage, and poor efficiency due to inadequate magnetic field management.
Innovation Solution
A three-core magnetic structure is used, with E cores and an I core inserted between them, allowing for precise gap control between the I core and E cores to manage magnetic flux, reducing core losses and improving efficiency by canceling out magnetic flux in certain legs, thereby enhancing the overall performance of power supply systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional structured transformers are coupled with inductor flux, then transformer functionality is achieved, but magnetic saturation and poor efficiency occur
Solution Approach 1:
The magnetic structure is divided into multiple separate cores (first core, second core, third core) instead of using a single structured transformer. Each core handles specific flux paths, preventing magnetic saturation in any single core while maintaining transformer functionality. The primary winding couples all three cores, while secondary windings are distributed across individual cores.
Solution Approach 2:
The patent transitions from a planar structured transformer design to a three-dimensional arrangement of separate cores with specific spatial relationships. The cores are positioned with defined gaps between them, creating a volumetric magnetic structure that allows independent flux management in each core, thereby avoiding saturation while maintaining coupling.
2Ease of operation
If structured transformers are used with inductor flux, then voltage transformation is achieved, but noise/ripple voltage increases
Solution Approach 1:
The secondary windings are segmented and distributed across multiple separate cores rather than being concentrated in a single structured transformer. This distribution allows each core to handle a portion of the total flux, reducing ripple and noise in the output voltage while maintaining the required voltage transformation ratio.
3Power
If traditional transformer designs are used, then basic transformation is achieved, but efficiency is poor
Solution Approach 1:
The magnetic path is segmented into multiple independent cores with controlled air gaps between them. This segmentation reduces magnetic core losses by preventing saturation and allowing optimized flux distribution. Each core can be independently designed for optimal performance, improving overall transformation efficiency while maintaining full power capability.
Solution Approach 2:
The patent introduces controllable air gaps between cores, changing the magnetic circuit parameters. By optimizing gap distances, the magnetic reluctance is controlled to prevent saturation while maintaining efficient coupling. This parameter adjustment allows the system to operate at higher efficiency points compared to traditional fixed-structure transformers.
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 effectively doubles current in a full-bridge current-doubler rectifier and provides a constant DC voltage in an interleaved two-switch forward converter, achieving lower magnetic losses and higher power density while reducing core losses and improving efficiency.
Implementation Method 1
A varying current in the first or primary winding creates a varying magnetic flux in the transformer and thus a varying magnetic field through a second or secondary winding. This varying magnetic field induces a varying electromotive force (EMF), or 'voltage,' in the secondary winding.
Implementation Method 2
a three-core magnetic structure is used, with E cores and an I core inserted between them, allowing for precise gap control between the I core and E cores to manage magnetic flux, reducing core losses and improving efficiency by canceling out magnetic flux in certain legs
Data Source
AI summary
An interleaved transformer or a transformer and integrated set of inductors formed via a magnetic structure comprising a set of E cores and an I core inserted between the set of E cores is provided in order to address issues that occur when a structured transformer is coupled together with inductor flux. Actual inductance exhibited by the transformers is controlled by a preselected precise gap between the I core and each of the E cores. The advantage of such a structured transformer cancels out the magnetic flux in certain legs of the magnetic structure requiring less magnetic material and thus, less core losses while improving the overall efficiency of a power supply.