Parallel Matrix Transformer-Inductor for High-Current Loss Reduction
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Solution Overview
Problem
Conventional power converters face challenges in handling high output currents due to large conduction losses, current sharing issues among parallel synchronous rectifiers, and high winding losses, particularly in high-step-down applications like computer servers.
Innovation Solution
The integration of a parallel matrix transformer and inductor structure using flux cancellation, where multiple elemental transformers are integrated into a single core, with primary windings arranged in series and secondary windings in parallel, and the use of a symmetrical structure to minimize AC winding resistance and leakage inductances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional power converters use parallel synchronous rectifiers to handle high output currents, then the current handling capability is improved, but conduction losses and current sharing issues increase
Solution Approach 1:
The patent divides the transformer into multiple elemental transformers (e.g., four 1kW elemental transformers to achieve 4kW output). Each elemental transformer has its own synchronous rectifier, distributing the current handling task and reducing conduction losses in each individual component while maintaining high overall power capability.
Solution Approach 2:
The patent integrates the inductor and transformer into a single combined structure where the inductor windings are formed using the same magnetic core and winding process as the transformer. This merging reduces total winding losses and improves efficiency while handling high output currents.
2Volume of stationary object
If multiple elemental transformers are integrated into a single core, then core volume is minimized, but manufacturing complexity increases
Solution Approach 1:
The magnetic core is divided into multiple pillars (e.g., four pillars for four elemental transformers), with each pillar serving a specific transformer winding. This segmentation allows modular construction while achieving compact integration and minimizing overall core volume through flux cancellation techniques.
Solution Approach 2:
The same magnetic core structure serves multiple functions: it supports both transformer windings and inductor windings, provides flux cancellation paths, and enables compact integration of multiple elemental transformers. This multi-functionality reduces the need for separate components and minimizes total core volume.
3Loss of energy
If primary windings are arranged in series and secondary windings in parallel, then conduction losses are reduced, but device complexity increases
Solution Approach 1:
The patent applies different winding configurations to different parts of the transformer: primary windings are connected in series to reduce current and associated losses, while secondary windings are connected in parallel to increase current handling capability and reduce conduction losses. This localized optimization of connection topology reduces overall winding losses while managing complexity through systematic design.
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 configuration reduces conduction losses, minimizes core volume, and allows for precise control of inductance values, enhancing the efficiency of power conversion in high-output current applications.
Implementation Method 1
The integration of a parallel matrix transformer and inductor structure using flux cancellation, where multiple elemental transformers are integrated into a single core
Implementation Method 2
a transformer is one example of a power converter
Data Source
AI summary
Various examples of an integrated parallel matrix transformer and inductor are disclosed herein. In one aspect, the transformer includes a first magnetic core having a first set of pillars of a first transformer and a second set of pillars of a second transformer and a second magnetic core having a first and second inductor pillar. The first and second magnetic cores can be separate or integrated into one core. The transformer also includes a planar winding structure. The planar winding structure may include a primary winding and a plurality of secondary windings. The primary winding can be configured to equally divide a primary current. The primary winding can extend a number of turns to conduct half of the primary current around the first inductor pillar and the first set of pillars and to conduct half of the primary current around the second inductor pillar and the second set of pillars.