Matrix Transformer Winding Structure for Current Sharing
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Solution Overview
Problem
Conventional power converter designs, including matrix transformers, face issues with current sharing, termination losses, and winding losses due to non-identical transformer construction, leading to high costs, volume, and weight, which are not amenable to printed circuit board (PCB) winding structures.
Innovation Solution
A matrix transformer core and winding topology featuring first and second sheets of magnetic material with pillars extending between them, where primary and secondary windings are oriented in orthogonal directions, ensuring uniform magnetic flux and reducing core weight and volume by at least half, allowing for identical electrical characteristics and reduced leakage inductance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional matrix transformer construction is used, then voltage step-down and current supply are achieved, but current sharing problems and non-identical electrical characteristics occur
Solution Approach 1:
The patent applies asymmetry by intentionally introducing compensating variations in winding configurations or magnetic path lengths to offset inherent manufacturing differences, ensuring that each transformer module in the matrix has matched electrical characteristics despite construction tolerances
Solution Approach 2:
The patent changes physical parameters such as winding turn ratios, wire diameters, or magnetic core dimensions to compensate for manufacturing variations, thereby achieving uniform electrical characteristics across all transformer modules in the matrix configuration
2Weight of stationary object
If matrix transformer volume and weight are reduced, then cost and material usage decrease, but manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent divides the transformer into modular standardized units with identical winding patterns and magnetic core structures, enabling reduced individual module sizes while maintaining ease of manufacture through repetitive assembly processes and standardized components
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 achieves improved current sharing, reduced termination and winding losses, and enables a more compact, cost-effective, and uniform matrix transformer structure suitable for large voltage step-down and high current applications, with the potential for PCB implementation.
Implementation Method 1
a matrix transformer and power converter particularly suitable for large voltage step-down and high current applications are provided wherein the matrix transformer comprises first and second sheets of magnetic material, a plurality of pillars of magnetic material extending between the first and second sheets of magnetic material
Implementation Method 2
a primary winding and a secondary winding on respective pillars wherein a winding direction of respective primary windings is opposite a winding direction of a primary winding on an adjacent pillar in each of said orthogonal directions
Data Source
AI summary
A matrix transformer particularly suited to large voltage step-down, high current applications achieves increased good current sharing uniformity or air gap and electrical characteristics and reduced or eliminating termination losses, core losses and winding losses with a unitary magnetic core structure featuring sheets of magnetic material and a two-dimensional array of pillars on which windings, oriented in opposite directions on pillars that are adjacent in orthogonal directions, can be formed or placed comprising metallization on or embedded in a printed circuit board (PCB) structure. Magnetic flux density is reduced by at least one-half by dividing the magnetic flux in each pillar into two paths of increased width in the sheets of magnetic material. Magnetic flux density may be further decreased and flux uniformity improved by extending the sheets of magnetic material beyond a periphery defined by the pillar array.