Integrated Magnetic Component Layout for Leakage Inductance
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Solution Overview
Problem
Transformer-reactor integrated magnetic elements struggle to simultaneously perform both transformer and reactor functions due to phase switching limitations.
Innovation Solution
A magnetic component design featuring multiple coils magnetically coupled with a core, where specific coils have non-overlapping regions in the coil radial direction, allowing for eccentric positioning and separate flux paths to achieve both transformer and reactor functions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If coils are arranged overlapping in the coil axial direction to achieve compact structure, then the device complexity is reduced, but the leakage inductance cannot be secured and simultaneous transformer-reactor function cannot be achieved
Solution Approach 1:
The patent transitions from one-dimensional axial overlap to two-dimensional radial offset arrangement. By positioning coil regions at different radial distances from the center, the design creates non-overlapping regions in the radial direction while maintaining compact axial structure, thereby securing leakage inductance without increasing overall device complexity.
Solution Approach 2:
The patent introduces asymmetric radial positioning of coil regions. Instead of symmetric axial alignment, the first and second coil regions are placed at different radial distances, creating asymmetric flux paths that generate the necessary leakage inductance while maintaining a compact integrated structure.
2Adaptability or versatility
If phase switching is used to alternate between transformer and reactor functions, then the magnetic component can serve multiple purposes, but it cannot perform both functions simultaneously
Solution Approach 1:
The patent designs a single magnetic component with a dual-function structure that can operate as both transformer and reactor simultaneously. The integrated core with specifically arranged coil regions enables both functions to coexist without requiring phase switching, providing continuous multi-functionality.
Solution Approach 2:
The magnetic component is segmented into distinct functional regions within the coils. The first coil region is optimized for transformer function while the second coil region provides reactor function, allowing both functions to operate independently and simultaneously within the same integrated component.
3Adaptability or versatility
If a transformer-reactor integrated magnetic element is used, then both functions can be achieved, but the specific coil regions must overlap in the axial direction which limits design flexibility
Solution Approach 1:
The patent resolves manufacturing constraints by moving from axial positioning to radial positioning for coil region arrangement. This dimensional change provides greater design flexibility as radial offsets can be more easily manufactured and adjusted while maintaining the integrated transformer-reactor functionality.
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 secures leakage inductance and enables simultaneous operation as both a transformer and a reactor, enhancing efficiency and functionality.
Implementation Method 1
a core forming a closed magnetic circuit
Implementation Method 2
a plurality of coils magnetically coupled with each other
Data Source
AI summary
A magnetic component includes a plurality of coils magnetically coupled with each other; and a core forming a closed magnetic circuit. At least part of portions in inner periphery side regions of respective plurality of coils are arranged overlapping with each other in a coil axial direction. When viewed from the coil axial direction, at least one of the coils is defined as a specific coil, and a region of the specific coil from an inner periphery edge to an outer periphery edge thereof in a coil radial direction is defined as a specific coil region, and the specific coil region has a portion which is not overlapped with at least one coil in the coil axial direction other than the specific coil that constitutes the specific coil region, in a region from the inner periphery edge to the outer periphery edge thereof in the coil radial direction.