Magnetic Integration Double-Ended Converter Design
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Solution Overview
Problem
Existing magnetic integration converters face significant losses and large leakage inductance due to winding inefficiencies, particularly in double-ended converters with wide-range input voltage applications.
Innovation Solution
A magnetic integration double-ended converter design featuring an inverter circuit with symmetrically working double ends, utilizing a magnetic core with three columns and energy storage air gaps, where the primary and secondary windings are wound around specific magnetic columns to minimize losses and leakage inductance, and synchronous rectifiers replace traditional rectifier diodes to reduce turn-on losses and achieve zero voltage drop clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional magnetic integration structure with windings wound around central column is used, then transformer function is achieved, but significant winding loss and large leakage inductance occur
Solution Approach 1:
The magnetic core is divided into three separate magnetic columns instead of a single central column. The primary winding is wound around the first magnetic column, while the first and second secondary windings are wound around the second and third magnetic columns respectively. This segmentation reduces magnetic path length and leakage inductance, thereby reducing winding losses.
Solution Approach 2:
The patent transitions from a traditional single-column vertical winding structure to a multi-column distributed winding structure. By distributing windings across multiple magnetic columns in a planar arrangement, the magnetic flux path is optimized, reducing leakage inductance and improving coupling efficiency without increasing overall device height.
2Productivity
If more primary windings are used to reduce leakage inductance, then energy transfer efficiency improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
Different magnetic columns serve different functions: the first magnetic column is dedicated to the primary winding for energy input, while the second and third magnetic columns accommodate secondary windings for energy output. This local functional differentiation optimizes magnetic flux distribution and reduces leakage inductance without requiring excessive windings, simplifying manufacturing.
3Power
If air gaps are added to magnetic columns to optimize magnetic properties, then energy storage capability improves, but magnetic flux leakage increases
Solution Approach 1:
The air gap is segmented and placed only in the third magnetic column rather than in all magnetic columns. This localized air gap design provides the necessary energy storage capability and prevents magnetic saturation while minimizing disruption to the overall magnetic flux path, thereby reducing magnetic flux leakage compared to having air gaps in all columns.
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 design reduces winding losses and leakage inductance, enabling high-efficient energy conversion by minimizing the number of primary windings and optimizing magnetic flux distribution, thereby enhancing overall converter efficiency.
Implementation Method 1
an integrated magnetic member having a magnetic core with three magnetic columns, including at least three windings and at least one energy storage air gap, where the primary winding and a first secondary winding are both wound around a first magnetic column
Implementation Method 2
the second magnetic column and a third magnetic column each define the at least one energy storage air gap therein
Data Source
Figure 1~3
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Figure 5
AI summary
A magnetic integration double-ended converter with an integrated function of a transformer and an inductor includes: an integrated magnetic member having a magnetic core with three magnetic columns, including at least three windings (NP, NS1, NS2) and at least one energy storage air gap, where a primary winding (NP) and a first secondary winding (NS1) are both wound around a first magnetic column or are both wound around a second magnetic column and a third magnetic column, and a second secondary winding (NS2) is wound around the second magnetic column and a total output current flows through the second secondary winding (NS2); an inverter circuit with double ends symmetrically working, acting on the primary winding (NP); and a group of synchronous rectifiers (SR1, SR2), gate electrode driving signals of which and gate electrode driving signals of a group of power switch diodes (S1, S2) of the inverter circuit with the double ends symmetrically working complement each other. The magnetic integration double-ended converter can reduce a loss of the windings and a leakage inductance of a primary side and a secondary side, thereby implementing high efficient conversion of energy.