Magnetic Device for Single-Stage 12V to 48V Power Conversion
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Solution Overview
Problem
Conventional power conversion modules with two-stage converters have low efficiency and limited applications due to high volume and cost, particularly when increasing bus voltage from 12V to 48V for high power density and efficiency requirements.
Innovation Solution
A magnetic device with a magnetic core assembly and winding assembly is designed to achieve voltage reduction and filtering functions using a single-stage converter, featuring a unique magnetic core structure and winding configuration that reduces volume and increases integration, allowing for high efficiency and expanded applications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a two-stage converter is used to increase bus voltage from 12V to 48V, then voltage conversion is achieved, but efficiency is low and volume is large
Solution Approach 1:
The patent combines the voltage conversion function and filtering function into a single magnetic device with integrated transformer and inductor structures. The magnetic core assembly includes both transformer windings and inductor windings sharing common magnetic paths, eliminating the need for separate two-stage converters and reducing overall system losses.
Solution Approach 2:
The magnetic device performs multiple functions simultaneously: voltage transformation (12V to 48V), current filtering, and power conversion. The magnetic core assembly serves both as a transformer for voltage conversion and as an inductor for filtering, making the device universal and eliminating the need for separate components.
2Power
If a two-stage converter is used to increase bus voltage from 12V to 48V, then voltage conversion is achieved, but device volume is large
Solution Approach 1:
The patent merges the transformer and inductor into a single magnetic device with shared magnetic core assembly. The magnetic legs and channels are common to both functions, significantly reducing the volume compared to separate two-stage converter components.
Solution Approach 2:
The inductor windings are nested within the same magnetic structure as the transformer windings. The magnetic core assembly contains both transformer and inductor functions in a nested configuration, maximizing space utilization and minimizing overall device volume.
3Ease of manufacture
If conventional magnetic device structure is used, then manufacturing is simple, but output ripple is high and filtering performance is poor
Solution Approach 1:
The magnetic core assembly features localized magnetic paths with different properties: the first magnetic path handles transformer flux while the second magnetic path handles inductor flux. The magnetic legs are positioned to create separate channels for different functions, optimizing filtering performance in specific local regions without complicating overall manufacturing.
Solution Approach 2:
The patent introduces a third dimension in magnetic flux management by creating stacked magnetic layers with distinct flux paths. The magnetic core assembly has vertical stacking of magnetic legs and channels, separating transformer and inductor flux in the vertical dimension while maintaining planar manufacturing simplicity.
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 magnetic device enables a power conversion module with reduced volume, low output ripple, high efficiency, and expanded application scope by achieving voltage reduction and filtering functions with a single-stage converter, compared to conventional two-stage converter systems.
Implementation Method 1
A magnetic device with a magnetic core assembly and winding assembly is designed to achieve voltage reduction and filtering functions
Data Source
AI summary
A magnetic device includes a magnetic core assembly and a winding assembly. The magnetic core assembly includes a first outer magnetic leg, a second outer magnetic leg, a first inner magnetic leg group and a second inner magnetic leg group. A first channel is formed between the first inner magnetic leg group and the first outer magnetic leg. A second channel is formed between the second inner magnetic leg group and the first inner magnetic leg group. A third channel is formed between the second inner magnetic leg group and the second outer magnetic leg. The winding assembly includes four coupled windings. The first terminals of the four coupled windings are located near a first lateral side of the magnetic core assembly. The second terminals of the four coupled windings are located near a second lateral side of the magnetic core assembly.