Matrix Transformer Core Layout for Controllable Leakage Inductance
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In high power resonant converters, magnetic losses due to transformers and inductors contribute significantly to inefficiency and size, particularly in secondary side winding losses and secondary rectifier devices, necessitating an improvement in magnetic structure design.
Innovation Solution
A matrix transformer with a five-leg magnetic core is introduced, where four core legs are used for elemental transformers and a fifth leg creates controllable leakage inductance without compromising power density, utilizing the center space for leakage flux and adjusting the cross-sectional area and air gap to control leakage inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional transformers and inductors are used in high power resonant converters, then power conversion function is achieved, but magnetic losses and device size increase significantly
Solution Approach 1:
The patent combines multiple transformers into a matrix transformer configuration where primary windings are connected in series and secondary windings are connected in parallel. This merging of multiple transformer units into a single integrated structure reduces the overall magnetic losses and decreases the total volume required for transformer and inductor components in the power converter.
Solution Approach 2:
The matrix transformer configuration serves multiple functions simultaneously: it provides power transformation, achieves the required inductance values for resonant operation, and reduces magnetic losses. This multi-functionality eliminates the need for separate inductor components, thereby reducing overall device size and energy losses.
2Loss of energy
If magnetic structure is optimized to reduce losses, then efficiency improves, but power density may be compromised
Solution Approach 1:
The patent applies local quality optimization by configuring windings specifically around selected core legs to minimize leakage flux in high-loss regions. The primary windings are arranged to concentrate magnetic flux where needed for efficient power transfer, while the secondary windings are positioned to reduce termination losses. This localized optimization maintains high power density while minimizing termination and core losses.
3Reliability
If leakage inductance is increased to improve converter performance, then resonant operation is enhanced, but magnetic losses increase
Solution Approach 1:
The patent optimizes the leakage inductance parameter by carefully designing the winding configuration and core structure. The matrix transformer configuration with series primary and parallel secondary windings provides controlled leakage inductance that enhances resonant operation and converter reliability. The parameter is optimized to achieve the necessary performance characteristics while minimizing energy losses through efficient magnetic coupling.
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 termination and core losses, achieves high power density, and allows for scalable configurations, enhancing the efficiency and performance of power converters.
Implementation Method 1
The winding arrangement shown in FIG. 4 with the core structure of FIG. 3 illustrates flux circulation between core legs with minimal leakage flux in the center core leg
Implementation Method 2
A transformer includes a magnetic core comprising a plurality of core legs and a leakage core leg. The transformer also includes a planar winding structure. The planar winding structure includes a primary winding and a plurality of secondary windings
Data Source
AI summary
Various examples of magnetic integration of matrix transformers with controllable leakage inductance are described. In one example, a transformer includes a magnetic core comprising a plurality of core legs and a leakage core leg. The leakage core leg is positioned among the plurality of core legs to control a leakage inductance of the transformer. The transformer also includes a planar winding structure. The planar winding structure includes a primary winding and a plurality of secondary windings. The primary winding and the plurality of secondary windings extend in a number of turns around the plurality of core legs, without a turn around the leakage core leg, to further control the leakage inductance of the matrix transformer.