Magnetic Assembly Heat Dissipation via Segmented X-I Core Structure
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Solution Overview
Problem
The integration of multiple magnetic elements in switching power supplies results in poor heat dissipation, affecting the service life and safety of the magnetic assembly due to limited heat dissipation area and inefficient heat removal.
Innovation Solution
A magnetic assembly comprising at least two X-type magnetic cores and one I-type magnetic core, with the X-type cores featuring a winding post and four side posts that form a closed magnetic circuit, providing strip-shaped and annular heat dissipation channels to enhance heat removal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If multiple magnetic elements are integrated to reduce size, then the volume of the magnetic assembly is reduced, but the heat dissipation performance deteriorates
Solution Approach 1:
The magnetic assembly is segmented into multiple independent magnetic elements (first magnetic element, second magnetic element, third magnetic element) that are arranged in a specific spatial configuration. Each magnetic element has its own winding and magnetic core structure, allowing heat to be distributed and dissipated from multiple separate regions rather than concentrated in a single integrated block, thus resolving the contradiction between compact volume and heat dissipation performance.
Solution Approach 2:
The magnetic elements are arranged in a three-dimensional configuration with specific spatial relationships (first magnetic element adjacent to second, third magnetic element positioned relative to others). This dimensional arrangement creates multiple heat dissipation pathways in different directions, allowing heat to escape through various surfaces and directions simultaneously, thereby maintaining compact volume while improving heat dissipation through spatial optimization.
2Power
If multiple magnetic elements are integrated to improve power density, then the power density is improved, but the heat removal efficiency deteriorates
Solution Approach 1:
The magnetic assembly is divided into multiple separate magnetic elements, each capable of handling specific power conversion tasks. This segmentation allows heat generated in each element to be managed independently, preventing heat accumulation that would occur in a fully integrated design, thus maintaining high power density while improving heat removal efficiency through distributed thermal management.
Solution Approach 2:
Each magnetic element is designed with its own specific structure and winding configuration optimized for its local function. The first, second, and third magnetic elements can have different characteristics tailored to their specific roles in the power conversion process, allowing each local region to optimize both power handling and heat dissipation according to its specific requirements, thereby resolving the contradiction between power density and heat removal efficiency.
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 enhanced heat dissipation channels improve the service life and safety of the magnetic assembly by effectively removing heat generated within the assembly, addressing the issue of poor heat dissipation in integrated magnetic elements.
Implementation Method 1
The at least two X-type magnetic cores and the at least one I-type magnetic core form a closed magnetic circuit
Implementation Method 2
two adjacent side posts of the X-type magnetic core are hollowed out to form a strip-shaped gap, which can provide a heat dissipation channel along an extending direction of the side posts
Data Source
AI summary
The present application provides a magnetic assembly, a manufacturing method thereof, a power module and a switching power supply. The magnetic assembly comprises at least two X-type magnetic cores and at least one I-type magnetic core; a winding is arranged on the X-type magnetic core, and the at least two X-type magnetic cores and the at least one I-type magnetic core form a closed magnetic circuit; the X-type magnetic core includes a winding post and four side posts surrounding the winding post, and one side of each of the four side posts is respectively connected with one side of the winding post to form a connection surface; the other sides of the four side posts and the winding post are respectively arranged in contact with the connection surface of the I-type magnetic core or other X-type magnetic cores. The application can solve the problem of poor heat dissipation after integration of a plurality of magnetic elements.