Magnetic Layer Winding Wire for High-Frequency Transformer Loss Reduction
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Solution Overview
Problem
High-frequency transformers in switching power supplies face significant coil and transformer losses due to high alternating current resistance, which limits the size reduction of these devices, as existing methods to minimize losses, such as decreasing element wire diameter, are constrained by the dominance of the proximity effect over the skin effect.
Innovation Solution
A winding wire with a stranded copper wire configuration, where at least one element wire has a magnetic layer and an extrusion coating layer of 40 to 400 μm thickness, effectively reduces alternating current resistance by suppressing both skin and proximity effects, allowing for smaller transformer sizes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the element wire diameter is decreased to suppress skin effect, then alternating current resistance is reduced, but the wire diameter cannot be sufficiently reduced due to proximity effect dominance
Solution Approach 1:
The patent applies composite materials by combining copper wire with magnetic material layers to form element wires. The magnetic material layer (with specific permeability μr≥10 and thickness 1-10 μm) composite structure modifies the electromagnetic characteristics of the wire, enabling effective suppression of both skin effect and proximity effect at high frequencies without requiring excessive diameter reduction
Solution Approach 2:
The patent changes physical parameters by specifying precise ranges for copper wire diameter (0.05-0.5 mm) and magnetic material layer thickness (1-10 μm), as well as magnetic permeability (μr≥10). These parameter optimizations balance the suppression of skin effect and proximity effect, achieving minimal alternating current resistance without over-reducing wire diameter
2Volume of stationary object
If the frequency is increased to reduce transformer size, then power transmission efficiency improves, but coil loss and transformer loss increase due to high alternating current resistance
Solution Approach 1:
The composite structure of copper wire with magnetic material layers enables the transformer to operate at high frequencies (several ten kHz or higher) with reduced coil loss. The magnetic material layer modifies the electromagnetic field distribution, suppressing proximity effect between adjacent wires in the coil, thereby maintaining low alternating current resistance even at high frequencies
Solution Approach 2:
By optimizing the copper wire diameter (0.05-0.5 mm) and magnetic material layer thickness (1-10 μm), the patent enables transformers to achieve compact sizes through high-frequency operation while keeping coil loss minimal. The parameter ranges are specifically designed to balance size reduction benefits against increasing alternating current resistance at high frequencies
3Loss of energy
If the number of element wires is increased to reduce losses, then alternating current resistance decreases, but the wire structure becomes more complex and harder to manufacture
Solution Approach 1:
The patent divides the conductor into multiple element wires (2-19 wires) twisted together to form a stranded wire. Each element wire has copper core with magnetic material layer, and the segmentation allows flexible configuration to achieve desired electrical performance while maintaining manufacturability through standardized twisting processes
Solution Approach 2:
The composite structure of each element wire (copper + magnetic material layer) provides consistent electromagnetic characteristics that simplify the design process. Rather than varying the number of wires indefinitely, the composite material approach allows optimization within a manageable range (2-19 wires) while achieving low alternating current resistance
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 proposed winding wire configuration significantly reduces alternating current resistance and associated losses in high-frequency transformers, enabling more compact and efficient switching power supplies by balancing direct and alternating current resistances.
Implementation Method 1
When the element wire diameter is decreased, a skin effect is suppressed during the passage of electric current
Implementation Method 2
in regard to a wire diameter at which a proximity effect becomes dominant rather than the skin effect in connection with the alternating current resistance
Data Source
AI summary
A winding wire having a stranded wire formed by twisting a plurality of element wires whose a copper wire having a wire diameter of 0.05 to 0.5 mm and an extrusion coating layer coating the plurality of the element wires,wherein at least one of the element wires has a magnetic layer on an outer circumference of the copper wire, and the thickness of the extrusion coating layer is 40 to 400 μm;as well as a coil and a transformer using the winding wire.