LLC Converter Magnetic Component With Adjustable Stray Inductance
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Solution Overview
Problem
Existing LLC resonant converters face limitations in high-current low-voltage applications due to high winding losses and reduced flexibility, as traditional integrated transformers require litz wire and alter stray inductance, leading to increased fringing fields and inefficiencies.
Innovation Solution
A converter component with a magnetic core and multiple electrical windings, where the second winding is wound around the first and second legs of the magnetic core, forming integrated resonant and magnetizing inductances, and providing adjustable stray inductance to enhance application flexibility, while maintaining low winding losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional integrated transformers use litz wire for primary and secondary windings, then the transformer can be integrated into a single component, but the degree of flexibility for usage scenarios decreases and it becomes inapplicable in high-current low-output voltage applications
Solution Approach 1:
The patent segments the transformer into separate magnetic components (resonant inductance component and magnetizing inductance component) rather than integrating them into a single transformer. This allows each component to be optimized independently and enables greater flexibility in application scenarios, particularly for high-current low-voltage gain applications where separate components provide better performance than integrated solutions.
2Adaptability or versatility
If the magnetic shunt is moved or repositioned to adjust stray inductance, then the stray inductance can be adjusted, but a large fringing field is generated which drastically increases winding losses
Solution Approach 1:
The patent extracts the stray inductance function from the transformer structure by introducing a separate resonant inductance component. This allows the transformer to maintain its original magnetic shunt position (avoiding large fringing fields and high winding losses) while achieving adjustable stray inductance through the separate resonant inductance component with adjustable air gap or turn ratio.
3Adaptability or versatility
If separate magnetic components are used for resonant inductance, magnetizing inductance, and transformer, then each component can be optimized independently, but the overall device complexity increases
Solution Approach 1:
The patent combines the resonant inductance and magnetizing inductance into a single integrated transformer structure, while maintaining the ability to independently optimize each function through separate winding arrangements. This merging approach reduces the number of separate magnetic components compared to fully separate implementations, while still providing the optimization benefits of independent component design.
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 efficient operation in high-current low-voltage applications by integrating resonant and magnetizing inductances, reducing winding losses, and increasing the flexibility of the converter component, making it suitable for a broader range of usage scenarios.
Implementation Method 1
The converter component includes a magnetic core, at least one first electrical winding, and at least one second electrical winding. The second electrical winding is wound so as to at least once and at least partially surround at least a first leg and a second leg of the at least three legs of the magnetic core.
Data Source
AI summary
The disclosure concerns a converter component, especially for LLC resonant converters, comprising a magnetic core with at least three legs, at least one first electrical winding, and at least one second electrical winding. Therein, the second 5 electrical winding is wound so as to at least once and at least partially surround at least a first leg and a second leg of the at least three legs of the magnetic core. The disclosure also concerns a converter comprising the converter component.