MANC Alloy Transformer Core for Leakage Inductance Control

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Solution Overview

Problem

Conventional transformer cores, such as air cores and gapped cores, fail to provide ideal characteristics for leakage inductance due to minimal permeability, large volume requirements, and increased electromagnetic interference and proximity losses.

Innovation Solution

The use of metal amorphous nanocomposite (MANC) alloy cores with predefined permeability, specifically ungapped soft magnetic cores, to engineer a transformer with controlled leakage inductance, allowing for higher power densities and reduced losses by guiding leakage flux and optimizing flux densities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If air cores are used to provide minimal permeability, then electromagnetic interference is reduced, but volume and turns required increase significantly

Engineering Contradiction:

Improveelectromagnetic interferenceVSAvoidcore volume

Core Design Contradiction:

Object-affected harmful factorsVSVolume of stationary object

Solution Approach 1:

The patent changes the permeability parameter of the core material by using MANC alloy with specifically engineered permeability values (μr = 5, 10, or 20) instead of air core (μr ≈ 1). This parameter change allows achieving the desired leakage inductance with significantly reduced core volume while maintaining controlled electromagnetic interference characteristics.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs metal amorphous nanocomposite (MANC) alloy as a composite material that combines the benefits of amorphous metal (high permeability control, low losses) with nanocrystalline structure. This composite material enables precise permeability engineering to achieve optimal leakage inductance with compact size.

Inventive Principle:

Principle #40Composite materials

2Loss of energy

If gapped cores are used to control flux distribution, then leakage inductance is adjusted, but fringing flux increases causing greater electromagnetic interference and proximity losses

Engineering Contradiction:

Improveproximity lossesVSAvoidelectromagnetic interference

Core Design Contradiction:

Loss of energyVSObject-affected harmful factors

Solution Approach 1:

Instead of using gapped cores that create fringing flux, the patent changes the approach by using ungapped MANC alloy cores with engineered permeability parameters. This eliminates the fringing flux problem while still achieving controlled leakage inductance through material property optimization rather than geometric modification.

Inventive Principle:

Principle #35Parameter changes

3Productivity

If conventional cores are used for transformer design, then manufacturing is simpler, but leakage inductance control and power density are suboptimal

Engineering Contradiction:

Improvepower densityVSAvoidcore structure complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent optimizes power density by changing the permeability parameter of the core material to specific values (μr = 5, 10, or 20) that are optimized for high-frequency operation. This enables higher power density without increasing structural complexity, as the MANC alloy cores maintain simple geometries while achieving superior performance through material property optimization.

Inventive Principle:

Principle #35Parameter changes

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 approach enables higher power densities, simpler packaging, and reduced electromagnetic interference by confining flux and minimizing eddy current losses, achieving tunable leakage inductance and improved efficiency in transformer designs.

Implementation Method 1

a core formed of at least one metal amorphous nanocomposite ('MANC') alloy, the at least one MANC alloy comprising a predefined permeability

Methodology Applied

Scientific EffectMagnetic permeability: Magnetism

Implementation Method 2

responsive to the secondary winding being open and current being applied to the primary winding, magnetizing flux in the transformer is primarily contained in the first core

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction