Multi-Leg Transformer Winding Layout for Compact LLC Converters
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Solution Overview
Problem
Existing power conversion apparatuses, particularly LLC resonant converters, face challenges in reducing the size of magnetic components such as resonant coils and transformers due to their large volume, which contributes significantly to the overall apparatus size.
Innovation Solution
A magnetic component design featuring a magnetic core with specific leg part configurations and winding arrangements, including a magnetic core with two base parts and five or six leg parts, and a winding structure that optimizes the layout of windings around these parts to minimize volume while maintaining functionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If frequency control is applied to stabilize output voltage over a wide input voltage range, then the power conversion apparatus can operate reliably, but a large voltage must be applied to the resonant coil which increases the magnetic flux at the magnetic core, requiring an increase in the effective cross-sectional area of the core and thus increasing the size of the resonant coil
Solution Approach 1:
The magnetic core is segmented into multiple limbs (first limb, second limb, third limb, fourth limb, and fifth limb) with windings distributed across different limbs. This segmentation allows the magnetic flux to be distributed across multiple paths rather than concentrated in a single core, reducing the required cross-sectional area of each individual limb while maintaining the overall magnetic coupling effectiveness.
Solution Approach 2:
The patent transitions from a conventional single-core resonant coil design to a multi-limb magnetic core structure with windings arranged in multiple spatial dimensions. The first winding is wound around the first, second, and third limbs, while the second winding is wound around the fourth and fifth limbs, creating a three-dimensional magnetic flux distribution that reduces the volume requirements.
2Power
If the resonant coil is designed with large inductance to meet power conversion requirements, then the power conversion performance is improved, but the coil part must be large in volume which increases the overall apparatus size
Solution Approach 1:
The patent combines the resonant coil and transformer into a single integrated magnetic component. The first winding serves as the resonant coil while the second winding serves as the transformer primary, sharing a common magnetic core structure. This merging eliminates the need for separate magnetic components, reducing the total volume while maintaining both resonant and transformation functions.
Solution Approach 2:
The magnetic core structure serves multiple functions simultaneously: it provides magnetic coupling for the resonant coil, magnetic coupling for the transformer, and distributed flux paths for both windings. The multi-limb structure enables the same magnetic component to fulfill multiple roles that would traditionally require separate components, achieving power conversion capability with reduced volume.
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 proposed design achieves a reduction in the size of magnetic components, thereby reducing the overall size of the power conversion apparatus without compromising performance.
Implementation Method 1
The first winding is, in a direction from the first coupling terminal to the second coupling terminal, wound around the first leg part, the second leg part, and the third leg part in a first winding direction, and around the fourth leg part and the fifth leg part in a second winding direction
Data Source
AI summary
A transformer includes a magnetic core, a first coupling terminal, a second coupling terminal, a first winding, and one or multiple second windings. The magnetic core includes two opposed base parts, and five leg parts including first to fifth leg parts disposed within opposed surfaces of the base parts and magnetically coupling the base parts. The second and third leg parts are disposed with the first leg part interposed therebetween in a first direction. The fourth and fifth leg parts are disposed with the first leg part interposed therebetween in a second direction. The first winding is, in a direction from the first coupling terminal to the second coupling terminal, wound around the first to third leg parts in a first winding direction, and around the fourth and fifth leg parts in a second winding direction. The second winding/windings is/are wound around the leg parts except the first leg part.