Magnetic Component with Segmented Core for Power Density
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Solution Overview
Problem
Existing power conversion devices face limitations in increasing power density due to structural bottlenecks in transformers, leading to poor efficiency and heat dissipation, along with high parasitic and thermal resistances, and increased production costs from EMI filters.
Innovation Solution
A magnetic component with a unique core structure featuring upper and lower magnetic core portions and four core columns, where windings form closed magnetic circuits with opposing AC flux directions, reducing core loss and thermal resistance, and a power conversion device design that incorporates these components to enhance efficiency and heat dissipation without additional EMI filters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the switch frequency of the switching circuit is increased to increase power density, then the size of the filter decreases and power density increases, but the core loss of the magnetic component increases and efficiency deteriorates
Solution Approach 1:
The magnetic core is divided into multiple core columns (first core column, second core column, third core column, fourth core column) with windings distributed across them. The windings are configured to form opposing AC flux directions in adjacent core columns, segmenting the flux paths to reduce overall core loss while maintaining high frequency operation.
Solution Approach 2:
The patent employs asymmetric winding configurations where windings on different core columns are arranged to produce opposing AC flux directions. This asymmetric arrangement creates flux cancellation effects that reduce core loss, allowing higher switching frequencies without proportional increases in core loss.
2Productivity
If the width and thickness of PCB windings are increased to increase power density, then the power density increases, but the parasitic resistance and thermal resistance of the windings increase
Solution Approach 1:
The patent utilizes the spatial dimension by distributing windings across multiple core columns in a three-dimensional arrangement. This dimensional distribution allows current paths to be optimized for lower resistance while improving thermal dissipation through better exposure to air, without increasing the planar footprint excessively.
Solution Approach 2:
Different core columns are assigned different winding configurations optimized for their local thermal and electrical characteristics. Windings are positioned to maximize exposure to air for heat dissipation in high-thermal-load areas, while maintaining appropriate current density distribution to minimize parasitic resistance.
3Productivity
If the number of PCB winding layers is increased to increase power density, then the power density increases, but the thermal resistance to the top radiator increases and heat dissipation deteriorates
Solution Approach 1:
The winding structure is segmented across multiple core columns rather than stacked in many layers on a single column. This segmentation distributes the thermal load vertically and exposes more winding surfaces to air, reducing thermal resistance to the radiator while achieving the required power density through spatial distribution.
4Productivity
If a single transformer structure is used to increase power density, then the power density increases, but the structural limitations become a bottleneck and efficiency deteriorates
Solution Approach 1:
The single transformer is segmented into multiple independent magnetic circuits, each formed by specific core columns and their associated windings. This segmentation allows each circuit to operate more efficiently within its optimal range, avoiding the structural bottlenecks of a monolithic transformer while collectively achieving high power density.
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 effectively reduces core loss, parasitic resistance, and thermal resistance, improving power conversion efficiency and heat dissipation while lowering production costs by utilizing a magnetic component with a U-core-like structure and opposing AC flux directions, thereby enhancing the power conversion device's performance.
Implementation Method 1
a first winding wound around any two of the four magnetic cores, so that a first closed magnetic circuit is formed between the two core columns wound by the first winding and the upper and lower magnetic core portions; and a second winding wound around remaining two of the four magnetic cores, so that a second closed magnetic circuit is formed
Implementation Method 2
opposing AC flux directions, reducing core loss
Data Source
AI summary
A magnetic component comprising: a magnetic core comprising an upper magnetic core portion, a lower magnetic core portion, and four core columns; a first winding wound around any two core columns which form a first closed magnetic circuit with the upper and lower magnetic core portions therebetween; and a second winding wound around remaining two core columns which form a second closed magnetic circuit with the upper and lower magnetic core portions therebetween. A sum of an AC flux peak-peak value within single core column of the first closed magnetic circuit, and an AC flux peak-peak value within single core column of the second closed magnetic circuit is larger than not only an AC flux peak-peak value within the upper magnetic core portion, but also an AC flux peak-peak value within the lower magnetic core portion. The first winding and the second winding are not connected in series directly.