Integrated Magnetic Core Structure for Leakage Inductance Control
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Solution Overview
Problem
Existing high-frequency transformers face challenges in adjusting leakage inductance without increasing loss, heat, and noise due to air gap adjustments, which affect performance and stability.
Innovation Solution
A magnetic core structure with isotropic magnetic materials and secondary auxiliary windings, allowing for precise modulation of leakage inductance by adjusting the number of turns, decoupling transformers, and using copper foil or Litz wire windings to minimize surface current concentration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the air gap of the magnetic core is increased to adjust leakage inductance, then the leakage inductance is improved, but the loss increases and noise is generated
Solution Approach 1:
The patent divides the magnetic core into multiple columns (first main magnetic core column, second main magnetic core column, first secondary magnetic core column, second secondary magnetic core column) connected by square magnetic core edge columns. This segmentation allows independent optimization of each column's properties while maintaining overall magnetic circuit integrity, enabling leakage inductance adjustment without air gap insertion.
Solution Approach 2:
The patent applies different magnetic material properties to different parts of the magnetic core. Specifically, the main and secondary magnetic core columns use materials with higher magnetic permeability, while the square magnetic core edge columns use materials with lower magnetic permeability. This local differentiation allows precise control of magnetic flux distribution and leakage inductance without introducing air gaps that would cause losses.
2Reliability
If the air gap of the magnetic core is increased to adjust leakage inductance, then the leakage inductance is improved, but the magnetic field stability deteriorates
Solution Approach 1:
The segmented magnetic core structure with multiple columns connected by edge columns provides a stable magnetic flux path without air gaps. The segmentation allows independent optimization of each column while maintaining overall field stability through the continuous magnetic circuit formed by the connecting edge columns.
Solution Approach 2:
The patent adjusts leakage inductance by changing the number of turns of the secondary auxiliary winding rather than changing the air gap. This parameter change approach allows precise control of leakage inductance while maintaining magnetic field stability, as the core remains fully closed without air gaps that would cause field distortion and instability.
3Reliability
If the air gap of the magnetic core is increased to adjust leakage inductance, then the leakage inductance is improved, but noise is generated
Solution Approach 1:
The segmented magnetic core structure eliminates the need for air gaps by providing multiple flux paths through the connected columns. This segmentation approach maintains magnetic circuit continuity while allowing leakage inductance adjustment through winding configuration, thereby eliminating air gap-related noise.
Solution Approach 2:
By using materials with different magnetic permeability in different parts of the core, the patent creates optimized local magnetic fields that reduce flux leakage and associated noise. The lower permeability edge columns act as flux barriers that contain the magnetic field, reducing noise generation while maintaining the desired leakage inductance through winding design.
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 improves power density and efficiency, reduces transformer loss, and enhances reliability by accurately controlling leakage inductance, minimizing noise and heat, and achieving miniaturization.
Implementation Method 1
the leakage inductance of the magnetic integrated high-frequency transformer is accurately modulated by adjusting the number of turns of the secondary auxiliary winding
Implementation Method 2
the magnetic permeability of the main magnetic core column and the secondary magnetic core column is greater than that of the square magnetic core edge column
Data Source
AI summary
This disclosure openly provides a magnetic core structure and a leakage inductance control method for a magnetic integrated high-frequency transformer, which involves the technical field of high-frequency transformers, including two square magnetic core edge columns, the first main magnetic core column, the second main magnetic core column, the first secondary magnetic core column and the second secondary magnetic core column; the two square magnetic core edge columns are arranged in parallel, the first main magnetic core column and the second main magnetic core column are placed in parallel and vertically in a middle of the two square magnetic core edge columns, and two ends of the first main magnetic core column and the second main magnetic core column are fixedly connected to two ends of the two square magnetic core edge columns respectively.