Three-Leg Magnetic Component With Inverted Windings for Low Leakage
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Solution Overview
Problem
Existing three-phase electric transformers face challenges with high leakage inductance, parasitic capacitance, and cooling difficulties, leading to inefficiencies and overheating due to concentrated magnetic flux in the central leg, which is exacerbated by the geometry of the E-shaped ferromagnetic core.
Innovation Solution
A magnetic component with two ferromagnetic half-cores stacked to form a core with three legs, where the primary and secondary windings on the central leg are inverted relative to the lateral legs, preventing magnetic flux from jumping between legs and reducing leakage inductance, allowing for easier integration and cooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If windings are stacked on an E-shaped ferromagnetic core, then the transformer is easy to integrate and cool, but leakage inductance becomes high
Solution Approach 1:
The patent inverts the winding directions on specific legs of the E-shaped core. Specifically, the primary and secondary windings on the central leg are wound in opposite directions compared to the lateral legs. This inversion creates opposing magnetic fluxes that cancel out the harmful concentrated leakage flux in the central leg, thereby reducing overall leakage inductance while maintaining the stacked winding architecture's integration and cooling advantages
2Productivity
If magnetic flux is concentrated in the central leg, then energy transfer is efficient, but overheating risks increase
Solution Approach 1:
The patent applies different winding directions to different legs of the E-shaped core. The lateral legs maintain one winding direction for efficient energy transfer, while the central leg uses inverted winding directions. This local differentiation allows the central leg to have reduced flux concentration (lower temperature) while other legs maintain efficient flux flow for energy transfer
3Productivity
If leakage inductance is used for resonant inductance, then energy transfer from primary to secondary is promoted, but magnetic flux concentration in legs increases
Solution Approach 1:
The patent converts the harmful concentrated leakage flux in the central leg into a beneficial controlled flux by inverting the winding directions. The inverted windings create opposing fluxes that cancel the harmful concentration effect, while still allowing the leakage inductance to function as resonant inductance for promoting energy transfer between primary and secondary circuits
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 configuration reduces magnetic flux concentration in the central leg, decreases overheating risks, and maintains efficiency by preventing leakage flux from interfering with controlled flux, making the transformer easier to integrate and cool, potentially eliminating the need for external inductive components in equilateral triangular designs.
Implementation Method 1
a magnetic core and coils through which flows an electric current that generates a magnetic field allowing electrical energy to be transferred from the primary circuit to the secondary circuit
Implementation Method 2
a ferromagnetic core of suitable shape
Data Source
AI summary
A magnetic component includes two ferromagnetic half-cores stacked and superposed to form a ferromagnetic core comprising three legs, namely two first legs and one second leg. Each leg is formed from two facing half-legs separated by a gap, and each leg incudes a primary winding and a secondary winding having a winding direction, on each of the half-legs forming the leg, respectively. The magnetic component is characterized in that, on the second leg, the primary winding and the secondary winding and their winding directions are inverted with respect to those of the first legs.