L-Core Magnetic Device for Compact Power Converter Design
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Solution Overview
Problem
Existing power converters require larger magnetic devices that occupy significant board space and prolong manufacturing time, necessitating a compact and flexible magnetic core design.
Innovation Solution
A magnetic device comprising L-core segments with legs of varying lengths and orientations, allowing for windings to be formed without a bobbin, and serving as a building block for multiple core geometries, which can be used in power converters to reduce complexity and size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If traditional magnetic devices are used in power converters, then the magnetic devices can store and transfer electrical energy, but they occupy significant board space and take up disproportionate manufacturing time
Solution Approach 1:
The magnetic core is divided into multiple L-core segments that can be independently manufactured and then assembled. Each L-core segment contains a portion of the windings, allowing for parallel manufacturing processes and reducing the overall manufacturing time while maintaining compact dimensions.
Solution Approach 2:
The L-core segments are designed to nest together in a compact arrangement, with each segment containing windings that are integrated within the segment structure itself, eliminating the need for external bobbins and reducing overall device footprint.
2Reliability
If traditional magnetic core designs are used, then the magnetic devices can function reliably, but they require complex structures with bobbins and extensive windings
Solution Approach 1:
The L-core segment integrates the magnetic core material, the winding support structure, and the winding itself into a single unified component. This merging eliminates the need for separate bobbins and reduces the number of assembly steps while maintaining electrical isolation and magnetic coupling.
Solution Approach 2:
Each L-core segment is designed as a self-contained unit where the magnetic path and windings are integrated within the segment structure, allowing the segment to function independently and simplifying the overall device 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
The solution enables the creation of compact magnetic devices that reduce board space usage and manufacturing time, while providing a flexible design for power converters, improving efficiency and scalability.
Implementation Method 1
Magnetic devices such as transformers and inductors are often employed in power converters to store and/or transfer electrical energy through the power converter
Implementation Method 2
a first L-core segment including a first leg and a second leg extending therefrom, and an opposing second L-core segment including a first leg and a second leg extending therefrom
Data Source
AI summary
A magnetic device and power converter employing the same. In one embodiment, the magnetic device includes a first L-core segment including a first leg and a second leg extending therefrom, and an opposing second L-core segment including a first leg and a second leg extending therefrom. The magnetic device also includes a winding formed around at least one of the first leg and the second leg of the first L-core segment or the second L-core segment.