Modular Matrix Transformer Assembly for Flux-Cancelled DC-DC Conversion
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Solution Overview
Problem
Conventional single-stage DC-DC power supplies face challenges with high output current and low voltage applications, experiencing high losses, poor heat dissipation, and low-frequency oscillations, which are exacerbated by unstable magnetic flux coupling and complex winding designs in modular transformers.
Innovation Solution
A DC-DC power supply with a modular transformer assembly featuring a novel flux cancellation scheme and modular matrix transformer, utilizing a primary circuit and secondary circuit connected through M transformer sets, with each transformer having multiple windings arranged in specific configurations to achieve flux cancellation and reduced ripple flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a single large transformer is used for energy conversion, then the power supply can handle high output current and low voltage applications, but it results in high losses and poor heat dissipation
Solution Approach 1:
The patent divides a single large transformer into multiple smaller modular transformer units (M transformer sets, each with N transformers). This segmentation allows the system to handle high output current through parallel connection of multiple units while each individual unit operates at optimal efficiency, reducing overall energy losses and improving heat dissipation through distributed thermal management.
2Loss of energy
If modular transformers are used to reduce losses, then energy efficiency improves, but magnetic flux coupling becomes unstable and design complexity increases
Solution Approach 1:
The patent combines multiple modular transformer units into a unified system with shared magnetic flux cancellation mechanisms. The even and odd numbered transformers are coupled through common magnetic paths, creating stable flux coupling that reduces ripple flux while maintaining modular benefits. This merging approach stabilizes the magnetic environment without sacrificing the energy efficiency gains from modularization.
Solution Approach 2:
The patent converts the potentially harmful ripple flux and magnetic oscillations into a beneficial cancellation effect. By strategically coupling even and odd numbered transformers with opposite polarity windings, the system causes ripple flux from one transformer to cancel ripple flux from another, transforming what would be a harmful interference into a useful flux reduction mechanism that improves efficiency.
3Adaptability or versatility
If modular transformer architecture is implemented, then scalability improves, but production costs increase
Solution Approach 1:
The patent segments the transformer system into standardized modular units that can be manufactured independently and assembled in parallel configurations. This segmentation enables scalable deployment where additional transformer sets can be added to meet increasing power requirements without redesigning the entire system, while standardized modules reduce per-unit manufacturing costs through economies of scale.
Solution Approach 2:
The patent designs universal transformer modules that can function in various configurations (single unit, parallel pairs, series-parallel combinations) to meet different power requirements. This multi-functionality allows the same basic module design to serve multiple application scenarios, reducing development and tooling costs while maintaining scalability across different power levels.
4Device complexity
If conventional single-stage DC-DC power supply is used, then system simplicity is maintained, but low-frequency oscillations and poor heat dissipation occur
Solution Approach 1:
The patent segments the power conversion function across multiple transformer units with distributed secondary circuits and output capacitors. This segmentation distributes heat generation and dissipation across multiple locations, preventing thermal concentration in a single point. The modular architecture maintains relative system simplicity while enabling effective thermal management through spatial distribution of heat sources.
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 solution provides enhanced efficiency, scalability, and reduced core volume, addressing issues of heat dissipation and oscillations, while maintaining system stability and reducing production costs.
Implementation Method 1
M transformer sets electrically connected in parallel between the primary circuit and the secondary circuit. Each of the M transformer sets includes N transformers
Implementation Method 2
a novel flux cancellation scheme and modular matrix transformer are introduced to offer scalability, reduced ripple flux, and enhanced efficiency
Data Source
AI summary
A DC-DC power supply and a transformer assembly are provided. The DC-DC power supply includes primary and secondary circuits and M transformer sets electrically connected in parallel between the primary and secondary circuits. Each transformer set includes N transformers, where M and N are positive integers. Each transformer includes first and second primary windings and first and second secondary windings. A connection node of the first and second secondary windings is electrically connected to an output capacitor of the secondary circuit, and each secondary winding is electrically connected to a corresponding secondary switch of the secondary circuit. The first and second primary windings in each transformer set are electrically connected in series. All transformers are arranged along a first direction, and each transformer includes columns arranged along the first direction with each extending along a second direction perpendicular to the first direction.