Magnetic Component Shielding for Flux Leakage in Power Converters
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Solution Overview
Problem
Magnetic components with spacers in power converters face issues with magnetic flux leakage, leading to increased temperature and losses in the wiring pattern, which cannot be effectively mitigated by existing techniques without compromising their thickness.
Innovation Solution
Incorporating a magnetic shielding member made of conductive material that covers the wiring pattern and is insulated from the core, reducing magnetic flux intersection by inducing eddy currents that cancel out leaking flux, thereby suppressing temperature rise without increasing the distance between the spacer and the wiring pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If the distance between the spacer and the board is increased to reduce magnetic flux leakage, then the temperature rise and losses are reduced, but the magnetic component becomes thicker
Solution Approach 1:
A magnetic shielding member is introduced as an intermediary element between the spacer and the board. This shielding member intercepts and redirects leakage magnetic flux before it reaches the wiring pattern on the board, thereby reducing temperature rise and losses without requiring increased distance between the spacer and board, thus maintaining component thickness
Solution Approach 2:
The magnetic shielding member is positioned within the existing structure of the magnetic component, nested between the spacer and the board. This nested configuration allows the shielding function to be integrated into the compact design without adding external thickness to the component
2Stability of the object's composition
If a spacer is provided in the core to make the inductance constant, then the inductance stability is improved, but magnetic flux leakage increases causing temperature rise and losses
Solution Approach 1:
The magnetic shielding member acts as a mediator that captures and redirects the leakage magnetic flux generated by the spacer, preventing it from intersecting the wiring pattern on the board, thereby eliminating the harmful effects while preserving the inductance-stabilizing function of the spacer
Solution Approach 2:
The magnetic shielding member converts the harmful leakage magnetic flux into beneficial eddy currents within itself, which generate an opposing magnetic field that cancels out the leakage flux, thereby transforming the harmful effect into a useful shielding mechanism
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 solution allows for thinner magnetic components while reducing magnetic flux intersection and associated temperature increases, maintaining efficiency and compactness.
Implementation Method 1
the magnetic shielding member covers a part or all of the wiring pattern in a plan view of the board, and is insulated from the wiring pattern and the core
Implementation Method 2
reducing magnetic flux intersection by inducing eddy currents that cancel out leaking flux
Implementation Method 3
When eddy currents flow in the wiring pattern, the temperature of the wiring pattern rises due to the Joule heat of eddy currents
Data Source
AI summary
A core includes a first core part, a second core part, and a spacer. The spacer is between the first core part and the second core part. A board has an opening in which the first core part is inserted, and includes a wiring pattern that wraps around the opening. A magnetic shielding member covers all of the wiring pattern in a plan view of the board, and is insulated from the wiring pattern and the core.