Leakage Transformer Shunt-Gap Layout for High Power Density
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Solution Overview
Problem
Existing leakage transformers require large distances to achieve high leakage inductance, which compromises power density, and existing solutions fail to efficiently manage proximity losses and common mode noise.
Innovation Solution
A leakage transformer design where the leakage inductance is determined by gaps defined by magnetic shunt elements rather than the distance between winding pillars, with windings split into multiple parts around pillars to reduce proximity losses and minimize capacitive coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If large distance is used between winding pillars to achieve high leakage inductance, then leakage inductance is improved, but power density deteriorates
Solution Approach 1:
Magnetic shunt elements are introduced as intermediary components between the primary and secondary windings. These shunt elements with defined gaps create the required leakage inductance without requiring large physical distances between winding pillars, thus maintaining high power density while achieving the desired leakage inductance
Solution Approach 2:
The leakage inductance is controlled by changing the gap parameters of the magnetic shunt elements rather than changing the physical distance between winding pillars. This parameter change allows precise control of leakage inductance while maintaining compact transformer dimensions for high power density
2Volume of moving object
If windings are placed close together to improve power density, then power density is improved, but proximity loss increases
Solution Approach 1:
The windings are divided into multiple separate winding segments placed around different winding pillars. This segmentation reduces the proximity effect between continuous windings by introducing magnetic shunt elements with gaps between adjacent winding sections, thereby reducing proximity losses while maintaining compact structure for high power density
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 achieves high power density and high leakage inductance while reducing proximity losses and common mode noise, allowing for efficient energy transfer without the need for large distances between windings.
Implementation Method 1
a leakage inductance of the leakage transformer is determined by the at least one gap
Implementation Method 2
The leakage inductance of the high leakage transformer is determined by a gap defined by the magnetic shunt elements
Implementation Method 3
The primary winding is wound around the plurality of first winding pillars. The secondary winding is wound around the plurality of second winding pillars
Data Source
AI summary
A leakage transformer is provided. The leakage transformer includes a first plate, a second plate, a plurality of winding pillars, a primary winding, a secondary winding and a plurality of magnetic shunt elements. Each magnetic shunt element is disposed between the two corresponding winding pillars, and there is a gap between every two neighboring magnetic shunt elements. Alternatively, the magnetic shunt element is disposed on the first plate and aligned with the corresponding winding pillar, and there is a gap between the magnetic shunt element and the second plate. A leakage inductance of the leakage transformer is determined by the gap.