Magnetic Element With Progressive Winding Turns
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Solution Overview
Problem
Conventional transformer designs face challenges in achieving high power density and efficiency due to uneven current distribution, increased losses, and insulation issues, particularly in high-voltage applications, where the complexity of winding structures and insulation requirements compromise the integrity and reliability of the transformer.
Innovation Solution
A magnetic element comprising a magnetic core with multiple windings where the number of turns decreases progressively from the innermost to the outermost winding, with terminals strategically positioned to minimize effective area reduction and conduction losses, and using a bendable substrate to simplify manufacturing and reduce footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If terminals are led from one side of the winding in conventional transformer designs, then the structure is simple to manufacture, but current distribution becomes non-uniform and losses increase
Solution Approach 1:
The patent divides the single terminal side into multiple terminal sides. Specifically, the first winding has first terminals led out from a first side, while the second winding has second terminals led out from a second side. This segmentation allows current to be distributed across multiple terminals rather than concentrating all current through one side, thereby reducing current density and associated losses while maintaining manufacturing simplicity.
2Power
If the number of turns in outer windings is increased to achieve higher voltage transformation, then voltage conversion capability improves, but insulation reliability deteriorates
Solution Approach 1:
The patent inverts the conventional winding arrangement by placing the winding with more turns (first winding) on the inside and the winding with fewer turns (second winding) on the outside. This inversion, combined with positioning terminals of the outer winding from a different side, creates better insulation spacing and reduces the risk of breakdown while still achieving the required voltage transformation ratio.
3Productivity
If switching frequency is increased to achieve higher power density, then power supply efficiency improves, but insulation requirements become more stringent
Solution Approach 1:
The patent addresses insulation challenges by utilizing spatial dimensionality - specifically, leading terminals from different sides (first side vs. second side) of the windings. This dimensional separation increases the effective insulation distance and reduces electromagnetic interference between windings, enabling higher switching frequencies to be used safely while maintaining insulation reliability.
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 enhances current distribution uniformity, reduces conduction losses, and improves insulation reliability, enabling higher power density and efficiency while maintaining structural integrity and reducing manufacturing complexity.
Implementation Method 1
a magnetic core, including at least one magnetic column extending along a first direction; a first winding surrounding the magnetic column; a second winding at least partially surrounding the first winding
Data Source
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AI summary
The present disclosure provides a magnetic element, including: a magnetic core with at least one magnetic column extending along a first direction; a first winding surrounding the magnetic column; a second winding at least partially surrounding the first winding; and a third winding at least partially surrounding the second winding. The number of turns of the second winding is less than or equal to the number of turns of the first winding. The number of turns of the third winding is less than or equal to the number of turns of the first winding.