Magnetic Core Assembly Layout for Low-Ripple Power Conversion
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Solution Overview
Problem
Conventional power conversion modules with single-stage conversion structures face challenges such as large size, high power loss, high AC current ripple, and low magnetic saturation capability, making them unsuitable for long-sized and high-density electronic devices.
Innovation Solution
A power conversion module with a magnetic device featuring a magnetic core assembly and windings arranged in a specific configuration to reduce AC current ripple and enhance magnetic saturation resistance, including a primary winding and secondary windings with distinct magnetic resistances and orientations, and a circuit board layout that reduces module size while increasing power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional single-stage power conversion module is used, then power conversion efficiency is improved, but the module size becomes large
Solution Approach 1:
The magnetic core is divided into multiple legs (first magnetic leg, second magnetic leg, third magnetic leg, fourth magnetic leg) with different magnetic resistances. The windings are segmented and wound around specific legs, creating a modular structure that reduces overall module size while maintaining efficient power conversion.
Solution Approach 2:
Different magnetic legs are designed with different magnetic resistances to optimize local magnetic flux distribution. The first and third magnetic legs have lower magnetic resistance, while the second and fourth magnetic legs have higher magnetic resistance, creating localized magnetic pathways that improve efficiency without increasing overall size.
2Ease of manufacture
If a conventional magnetic device structure is used, then the module is simple to manufacture, but power loss is large
Solution Approach 1:
The magnetic core is segmented into multiple legs with different magnetic resistances, allowing optimized magnetic flux paths that reduce power loss. The winding structure is also segmented, with different windings placed on different legs, maintaining manufacturing simplicity while improving efficiency.
Solution Approach 2:
The magnetic resistance parameter is varied across different magnetic legs. The first and third magnetic legs have lower magnetic resistance, while the second and fourth magnetic legs have higher magnetic resistance. This parameter variation optimizes magnetic flux distribution and reduces power loss without complicating manufacturing.
3Volume of moving object
If a conventional magnetic device structure is used, then the module is compact, but AC current ripple is large
Solution Approach 1:
The magnetic core is divided into four legs with alternating magnetic resistance values. This segmentation creates multiple magnetic flux paths that work together to cancel ripple currents, achieving low ripple in a compact form factor.
Solution Approach 2:
The magnetic device employs asymmetric magnetic resistance distribution across the four legs. The first and third legs have lower magnetic resistance, while the second and fourth legs have higher magnetic resistance. This asymmetric design creates balanced magnetic flux distribution that reduces AC current ripple while maintaining compact size.
4Device complexity
If a conventional magnetic device structure is used, then the module is simple in design, but magnetic saturation capability is low
Solution Approach 1:
The magnetic core is segmented into four legs with different magnetic resistances, creating multiple independent magnetic flux paths. This segmentation allows the device to handle higher magnetic flux without saturation, improving reliability while maintaining relatively simple design and manufacturing.
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 current ripple and enhances the module's ability to withstand magnetic saturation, enabling the power conversion module to be applied effectively in high-density applications like display cards or ASIC cards with improved efficiency and compact size.
Implementation Method 1
The magnetic device includes a magnetic core assembly, a primary winding, a first secondary winding and a second secondary winding... The primary winding is wound around the first magnetic leg and the third magnetic leg through the connection region
Implementation Method 2
A magnetic resistance of each of the second magnetic leg and the fourth magnetic leg is greater than a magnetic resistance of each of the first magnetic leg and the third magnetic leg
Data Source
AI summary
A magnetic device includes a magnetic core assembly, a primary winding, a first secondary winding and a second secondary winding. The magnetic core assembly includes a first magnetic cover, a second magnetic cover, a first magnetic leg, a second magnetic leg, a third magnetic leg and a fourth magnetic leg. The primary winding is wound around the first magnetic leg and the third magnetic leg. A first terminal of the first secondary winding is disposed between the first magnetic leg and the second magnetic leg. A second terminal of the first secondary winding is disposed between the third magnetic leg and the fourth magnetic leg. A first terminal of the second secondary winding is disposed between the first magnetic leg and the fourth magnetic leg. A second terminal of the second secondary winding is disposed between the second magnetic leg and the third magnetic leg.