Multiphase Power Converter Transformer Core Design
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Solution Overview
Problem
Conventional multiphase power converter transformers have limitations in core area and volume, leading to reduced power density and efficiency due to separate magnetic cores for each phase, which increases the size and core losses.
Innovation Solution
A transformer design with a magnetic structure featuring a top member, bottom member, and legs extending between them, where coils are wound around inner legs, allowing for increased effective core area and reduced volume, enabling magnetic flux sharing and cancellation, thus enhancing power density and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate magnetic cores are used for each phase, then each transformer can operate independently, but the overall device volume and core losses increase
Solution Approach 1:
The patent combines multiple separate magnetic cores into a single shared magnetic core that accommodates windings from multiple phases. This merging approach reduces the total volume by eliminating redundant core structures while maintaining the electrical isolation and independent operation of each phase through proper winding arrangements and magnetic circuit design.
2Reliability
If separate magnetic cores are used for each phase, then each transformer can operate independently, but the power density decreases
Solution Approach 1:
By merging multiple separate cores into one shared core structure, the patent achieves more efficient space utilization and reduces overall transformer volume. This volume reduction directly increases power density while the magnetic circuit is designed to maintain independent phase operation through proper flux paths and winding configurations.
3Ease of manufacture
If separate magnetic cores are used for each phase, then manufacturing is simpler, but core losses increase
Solution Approach 1:
The patent merges multiple cores into a single shared magnetic core, which reduces the total amount of magnetic material required and simplifies the overall manufacturing process. The shared core design also reduces core losses by eliminating redundant magnetic paths and reducing the total core volume, while maintaining independent phase operation through proper magnetic circuit design.
4Volume of stationary object
If a shared magnetic core is used, then volume and core losses are reduced, but the magnetic structure becomes more complex
Solution Approach 1:
The shared magnetic core is designed with segmented magnetic paths and distinct winding regions that allow each phase to operate independently. This segmentation approach simplifies the overall structure by using a single core instead of multiple separate cores, while maintaining the functional independence of each phase through clearly defined magnetic circuits and winding arrangements.
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 design achieves a 33% larger effective core area or 33% reduced volume compared to conventional transformers, resulting in higher power density and efficiency with reduced core losses and slower switching frequencies.
Implementation Method 1
a transformer for the plurality of subconverters. The transformer includes a magnetic structure, a first coil electrically coupled to the input circuit or the output circuit of one of the subconverters, and a second coil electrically coupled to the input circuit or the output circuit of another one of the subconverters
Data Source
AI summary
A transformer for a multiphase power converter includes a magnetic structure, a first coil configured to electrically couple to an input circuit or an output circuit of a subconverter of the multiphase power converter, and a second coil configured to electrically couple to an input circuit or an output circuit of another subconverter of the multiphase power converter. The magnetic structure includes a top member, a bottom member, and legs extending between the top member and the bottom member in substantially the same direction. The legs include two outer members and two inner members. The first coil is wound about one of the two inner members of the magnetic structure, and the second coil is wound about the other one of the two inner members of the magnetic structure. Other example transformers, and multiphase power converters including transformers are also disclosed.