Magnetic Unit With Symmetrical Windings For Low AC Loss
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Solution Overview
Problem
High-frequency and high-power density magnetic components in data centers face challenges in achieving low winding loss and high copper utilization due to limitations in winding gap design and magnetomotive force (MMF) distribution, leading to increased energy consumption and space occupancy.
Innovation Solution
A magnetic unit design featuring Q magnetic legs with windings symmetrically disposed around them, ensuring uniform MMF distribution and reduced AC loss, thereby enhancing copper utilization and minimizing DC resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If winding gap is reduced to improve copper utilization, then copper foil utilization increases, but PCB thickness and manufacturing complexity increase
Solution Approach 1:
The patent transitions from planar 2D winding layout to 3D multi-layer stacked winding structure. By utilizing vertical stacking of copper foils in multiple layers with magnetic cores positioned between layers, the design achieves higher copper utilization without increasing PCB thickness proportionally. The windings are arranged in alternating layers with magnetic cores, creating a three-dimensional magnetic path that improves efficiency while maintaining compact form factor.
Solution Approach 2:
The patent implements nested arrangement where magnetic cores are positioned within and between winding layers. The magnetic cores are embedded in the PCB structure, with windings wrapped around them in multiple layers. This nested configuration allows the windings to be closely coupled with the magnetic cores, maximizing copper utilization and minimizing winding gaps without requiring excessive PCB thickness.
2Loss of energy
If number of winding layers is increased to reduce DC resistance, then copper utilization improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent divides the winding structure into multiple discrete copper foil layers, each wrapped around specific magnetic cores. The windings are segmented into primary and secondary winding sections on different layers, with each layer independently manufacturable. This segmentation allows for modular assembly and reduces the complexity of manufacturing high-layer-count PCBs, as each layer can be processed and assembled separately.
Solution Approach 2:
The patent introduces magnetic cores as intermediary elements between winding layers. These cores serve as both magnetic flux conduits and mechanical anchors for the windings. The magnetic cores facilitate the coupling between different winding layers, enabling efficient magnetic linkage while simplifying the assembly process. The cores act as mediators that hold the multi-layer winding structure together, reducing the need for complex inter-layer connections.
3Power
If switching frequency is increased to improve power density, then power delivery capability improves, but AC loss in windings increases
Solution Approach 1:
The patent optimizes the local magnetic field distribution by positioning magnetic cores at specific locations within the winding structure. The magnetic cores are strategically placed to concentrate and guide magnetic flux through high-permeability paths, reducing leakage flux and improving coupling between windings. This local optimization of magnetic field quality reduces AC loss by minimizing eddy currents and hysteresis losses in the windings, enabling higher switching frequencies with acceptable loss levels.
Solution Approach 2:
The patent employs composite construction combining copper foils, magnetic core materials, and insulation layers in a multi-layer stacked configuration. The magnetic cores provide high-permeability paths that confine magnetic flux, while the copper windings provide low-resistance current paths. This composite structure reduces AC loss by improving magnetic coupling and reducing leakage, enabling the system to operate at higher switching frequencies with lower losses compared to conventional single-layer designs.
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 magnetic unit achieves low AC loss and high copper utilization, resulting in reduced energy consumption and compact design suitable for high-power density applications.
Implementation Method 1
a second winding magnetically coupled with the first winding and wound around the Q magnetic legs
Data Source
AI summary
The present disclosure relates to the field of power electronic technology, provides a magnetic unit, including: a magnetic core and a winding, the magnetic core includes Q magnetic legs arranged in a row, where Q is a natural number and Q≥2, and the winding includes a first winding and a second winding, where the first winding is magnetically coupled with the second winding, and the first winding is wound around the Q magnetic legs while the second winding is wound around the Q magnetic legs. The first winding between any two adjacent magnetic legs is generally symmetrically disposed at both sides of the symmetric plane between the any two adjacent magnetic legs, thereby the magnetomotive force (MMF) distribution between any two adjacent magnetic legs is uniform.