Magnetic Core Gap Distribution for Lower AC Losses
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Solution Overview
Problem
Conventional magnetic components for power converters suffer from high AC losses and low power density, inefficient cooling, and arduous and expensive manufacturing and assembly processes due to linear inductance and inefficient air gap configurations.
Innovation Solution
A magnetic component with a gap distribution device comprising magnetic pieces and a holding frame that distributes gaps between magnetic core surfaces, allowing for efficient cooling and cost-effective manufacturing, featuring non-linear inductance and improved power density through optimized gap configurations and fringing field shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional air gap configurations are used in magnetic cores, then the inductance is controlled and saturation current is increased, but AC copper losses are high and power density is low
Solution Approach 1:
The gap distribution device segments the air gap into multiple smaller gaps by distributing magnetic pieces within the gap region. This segmentation reduces AC copper losses by minimizing the skin effect and proximity effect in the windings, while maintaining adequate power density through optimized gap distribution.
Solution Approach 2:
The magnetic pieces are strategically distributed at specific locations within the air gap to create non-uniform magnetic field distribution. This local quality optimization reduces AC losses in critical regions while maintaining overall inductance and power density requirements.
2Temperature
If conventional air gap configurations are used, then inductance control is achieved, but the magnetic component cannot be cooled efficiently
Solution Approach 1:
The gap distribution device acts as an intermediary structure within the air gap that provides thermal conduction paths. The magnetic pieces and holding frame create thermal bridges that facilitate heat transfer from the windings to the magnetic core and ultimately to the external cooling system, improving cooling efficiency without compromising inductance control.
3Ease of manufacture
If coils are used to hold components within the gap, then component positioning is achieved, but manufacturing and assembly procedures are arduous and expensive
Solution Approach 1:
The gap distribution device merges multiple functions into a single component: it distributes the air gap, positions magnetic components, provides thermal conduction paths, and serves as a structural support. This consolidation eliminates the need for separate coil assemblies and simplifies manufacturing and assembly procedures while reducing costs.
Solution Approach 2:
The holding frame structure of the gap distribution device is designed to automatically position and secure magnetic pieces within the air gap through its geometric configuration. This self-positioning capability eliminates the need for complex assembly procedures and specialized positioning mechanisms, reducing manufacturing complexity and cost.
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 reduces AC losses, enhances power density, and simplifies manufacturing and cooling processes by distributing gaps within the magnetic component, providing efficient thermal management and improved magnetic characteristics.
Implementation Method 1
A magnetic component comprises at least one magnetic core, wherein at least one gap is formed between surfaces of the magnetic core(s)
Implementation Method 2
At least one electrical winding is wound around the at least one magnetic core and/or the at least one holding frame of the gap distribution device
Data Source
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AI summary
The invention concerns a magnetic component (1) comprising at least one magnetic core (2), wherein at least one gap (3) is formed between surfaces (4), especially opposing end surface(s) and/or side surface(s), of the magnetic core(s) (2), wherein a direction extending between said surfaces (4) is defined as a gap extension direction (5), a gap distribution device (6) comprising at least one magnetic piece (7) and at least one holding frame (8) configured to hold the at least one magnetic piece (7), wherein the gap distribution device (6) is arranged within said at least one gap (3) of the at least one magnetic core (2) such that the at least one magnetic piece (7) is arranged within said gap (3), and at least one electrical winding (9) wound around the at least one magnetic core (2) and/or the at least one holding frame (8) of the gap distribution device (6).