LLC Converter Magnetic Structure With Distributed Air Gaps
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing LLC series resonant converters face challenges in reducing the size and weight of magnetic devices while maintaining energy conversion efficiency, as the magnetic device occupies a significant space and incurs high manufacturing costs.
Innovation Solution
A magnetic device with a horizontal distributed type air gap structure, featuring a base plate with concave portions and winding columns with air gaps, and a specific wiring arrangement for rectifier switches to reduce volume, weight, and copper loss, while maintaining efficiency through center-tap rectifier circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the magnetic device uses a conventional solid base plate structure, then the structural strength is sufficient, but the volume and weight of the magnetic device are large
Solution Approach 1:
The base plate is designed with a honeycomb structure containing multiple through holes, transforming the solid structure into a porous configuration. This reduces the volume and weight of the base plate while maintaining structural strength through the distributed hexagonal cells that provide mechanical support. The honeycomb structure allows the base plate to achieve optimal balance between weight reduction and structural integrity.
Solution Approach 2:
The base plate is segmented into multiple regions by dividing it into a honeycomb pattern with repeated hexagonal units. This segmentation creates multiple small structural elements that collectively provide the necessary mechanical strength while reducing the overall material volume. The modular honeycomb structure allows for optimized distribution of structural support across the base plate area.
2Volume of moving object
If the base plate volume is reduced through concave portions and honeycomb structure, then the device achieves miniaturization, but the core loss increases
Solution Approach 1:
The invention changes the geometric parameters of the base plate by introducing concave portions and honeycomb structures, optimizing the balance between volume reduction and core loss. The specific design parameters of the honeycomb cells and concave regions are tuned to minimize the impact on magnetic flux paths while achieving significant volume reduction. This parameter optimization ensures that the increase in core loss is offset by reductions in other loss components.
Solution Approach 2:
The invention merges the functions of structural support and magnetic flux guidance by integrating the honeycomb structure directly into the base plate design. The base plate with honeycomb structure serves dual purposes: providing mechanical support while also guiding magnetic flux through its optimized geometry. This merging allows the structure to contribute positively to magnetic circuit performance while minimizing volume.
3Ease of manufacture
If the magnetic device structure is simplified for manufacturing, then the manufacturing cost is reduced, but the energy conversion efficiency may be affected
Solution Approach 1:
The magnetic device is segmented into modular components including the base plate with honeycomb structure, winding columns, and cover plate that can be manufactured separately and assembled. This segmentation enables simplified manufacturing of individual components using standard processes while maintaining the overall device efficiency through precise assembly. The modular approach reduces manufacturing complexity and cost.
Solution Approach 2:
The base plate with honeycomb structure performs multiple functions: structural support, magnetic flux guidance, and thermal management. This multi-functionality reduces the need for additional separate components, simplifying the overall device structure and reducing manufacturing cost. The universal design of the base plate integrates several functions into a single element, maintaining efficiency while reducing complexity.
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 design achieves miniaturization of the LLC series resonant converter, reduces manufacturing costs, and enhances operating efficiency by offsetting increased core loss with reduced copper loss, without affecting overall efficiency.
Implementation Method 1
a primary winding and a secondary winding wound around the first winding column and the second winding column
Implementation Method 2
The first winding column is disposed between the base plate and the cover plate and includes a first air gap. The second winding column is disposed between the base plate and the cover plate and includes a second air gap
Data Source
AI summary
A magnetic device includes a base plate, a cover plate, a first winding column, a second winding column, a primary winding, a secondary winding and a supporting column. The base plate, having a first concave portion, is opposite to the cover plate. The first winding column and the second winding column are disposed between the bottom plate and the cover plate, respectively. The primary winding and the secondary winding are wound around the first winding column and the second winding column. The supporting column is disposed between the base plate and the cover plate. A first concave portion concaves from a first side of the base plate towards the first winding column and the second winding column along multiple directions. The primary winding and the secondary winding are wound and stacking along an extension direction of the first winding column and the second winding column.