Magnetic Element Winding Configuration for Power Module Loss Reduction
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Solution Overview
Problem
Conventional transformer designs face challenges in achieving high power density and efficiency due to issues with current distribution, terminal losses, and insulation reliability, particularly in high-voltage and high-current applications.
Innovation Solution
The design incorporates a magnetic element with windings arranged such that the innermost winding has the most turns, with fewer turn windings in outer layers, and terminals are strategically positioned to minimize effective area reduction and conduction losses, while ensuring adequate insulation between windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If terminals are led from one side of the winding in conventional transformer designs, then the structure is simple, but winding current distribution becomes non-uniform and terminal losses increase
Solution Approach 1:
The patent divides the terminal structure into multiple segments by providing multiple terminals (first terminal and second terminal) for each winding, distributing the current flow across multiple paths rather than concentrating it in a single terminal, thereby reducing terminal losses and improving current distribution uniformity
Solution Approach 2:
The patent optimizes the local quality of terminal arrangement by positioning terminals at specific locations (e.g., opposite sides or distributed positions) to achieve uniform current distribution across the winding cross-section, reducing eddy currents and improving overall efficiency
2Ease of operation
If terminals are made longer to facilitate connection, then ease of operation improves, but terminal losses increase
Solution Approach 1:
The patent uses multiple terminals instead of extending single terminals excessively, achieving the connection function with adequate length while distributing current across multiple shorter terminal paths, thereby reducing overall terminal losses while maintaining ease of operation
3Loss of energy
If inner winding terminals extend beyond outer winding boundaries, then current distribution improves, but insulation reliability deteriorates
Solution Approach 1:
The patent introduces an insulating structure as an intermediary element between the inner and outer windings, allowing the inner winding terminals to extend beyond outer winding boundaries for improved current distribution while maintaining adequate insulation distance through the insulating structure, thereby preserving both current distribution uniformity and insulation reliability
4Volume of stationary object
If switching frequency is increased to reduce power supply volume, then power density improves, but efficiency deteriorates
Solution Approach 1:
The patent optimizes winding parameters (turns ratio, terminal arrangement, winding configuration) to reduce losses at high switching frequencies, allowing the power supply to operate efficiently at higher frequencies with improved power density while minimizing the negative impact on conversion efficiency through optimized electrical parameters
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
This configuration reduces terminal losses, enhances current distribution, and improves insulation reliability, leading to increased efficiency and power density in power modules.
Implementation Method 1
a magnetic element with windings arranged such that the innermost winding has the most turns
Data Source
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AI summary
The present disclosure provides a magnetic element, including: a magnetic column (91, 92) extending along a first direction (43); a first winding (45) surrounding the magnetic column, connected to a first terminal (29, 212) located on a first side of the magnetic element, and the first terminal has a first projection of the first terminal on a first side surface of the magnetic element; and a second winding (46) surrounding the magnetic column and at least partially outside the first winding, wherein the second winding has a first projection of the second winding on the first side surface of the magnetic element, the first projection of the first terminal is at least partially outside the first projection of the second winding, the second winding is a flatwise-wound winding, and the number of turns of the first winding is greater than or equal to the number of turns of the second winding.