Parallel Winding Transformer for Power Density Bottlenecks
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Solution Overview
Problem
Existing power conversion devices face limitations in increasing power density due to structural bottlenecks in transformers, leading to poor efficiency and heat dissipation, along with high parasitic and thermal resistances, and increased production costs.
Innovation Solution
A magnetic component and power conversion device design featuring transformers with parallel-connected primary windings and center-tap secondary windings, where the deviation in inductance between the windings is controlled within 30%, allowing for reduced core loss, parasitic resistance, and thermal resistance, and improved heat dissipation through a U-core-like magnetic core structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the switch frequency of the switching circuit is increased to increase power density, then the size of the filter decreases and power density increases, but the structure limitation of a single transformer becomes a bottleneck and the transformer cannot handle higher frequencies effectively
Solution Approach 1:
The patent divides a single transformer into multiple transformers (first transformer and second transformer) with parallel-connected primary windings. This segmentation allows each transformer to operate at lower individual frequencies while the overall system achieves high power density, overcoming the frequency limitation of single transformers.
Solution Approach 2:
The patent combines multiple transformers in parallel configuration where the primary windings are connected in parallel. This merging approach allows the system to handle higher power densities by distributing the load across multiple transformer units, eliminating the structural bottleneck of a single transformer.
2Power
If the width and thickness of PCB windings of the single transformer are increased to increase power density, then the power density increases, but the winding resistance does not reduce significantly and thermal resistance to the radiator increases
Solution Approach 1:
The patent segments the winding structure into multiple parallel windings across multiple transformers. This segmentation reduces the current density in each individual winding, thereby reducing parasitic resistance and thermal resistance without requiring excessive increases in winding width or thickness.
Solution Approach 2:
The patent transitions from a single thick winding structure to a multi-layer parallel winding structure. By distributing windings across multiple transformers and layers, the design reduces thermal resistance to the radiator while maintaining power density, effectively solving the thermal management issue.
3Power
If the number of PCB winding layers of the transformer is increased to increase power density, then the power density increases, but the production cost increases and the thermal resistance to the top radiator increases
Solution Approach 1:
The patent segments the transformer into multiple units with parallel connections, achieving high power density without excessively increasing the number of winding layers in a single transformer. This approach controls production costs while improving heat dissipation by distributing thermal load across multiple units.
Solution Approach 2:
The patent combines multiple transformer units with parallel primary windings to achieve high power density. This merging approach allows for better heat dissipation management and controlled production costs compared to stacking excessive layers in a single transformer.
4Temperature
If a U-core structure is used instead of E-core to improve heat dissipation, then the PCB windings are more exposed to air and heat dissipation improves, but the core loss of the magnetic core increases
Solution Approach 1:
The patent uses multiple U-core structures instead of a single large core. This segmentation allows each U-core to have better heat dissipation characteristics while the combined system maintains lower overall core loss through distributed magnetic flux paths.
Solution Approach 2:
The patent combines multiple U-core structures with parallel windings to achieve both good heat dissipation (through exposed windings) and low core loss (through distributed magnetic circuits). The merged system benefits from the advantages of U-core exposure while mitigating the core loss issue.
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 effectively reduces core loss, parasitic resistance, and thermal resistance, enhancing the efficiency and heat dissipation of power conversion devices while minimizing production costs by utilizing a magnetic core structure similar to multiple U-cores with opposite AC flux directions.
Implementation Method 1
the primary winding of the transformer transmits a received electric energy to a secondary winding
Implementation Method 2
a product of a variation of a flux density borne on the magnetic component, such as, a transformer, etc., within the power conversion device and a working frequency of the magnetic component may rise substantially
Data Source
AI summary
The present invention relates to a power conversion device, comprising: at least one resonant circuit comprising at least one resonant inductor and at least one resonant capacitor; a first transformer comprising a first primary winding which is electrically connected to the resonant circuit and at least one first secondary winding; and a second transformer comprising a second primary winding which is electrically connected to the resonant circuit and at least one second secondary winding, the second primary winding and the first primary winding are connected in parallel and have the same number of coil turns, and the second secondary winding and the first secondary winding have the same number of coil turns; an deviation of inductance between the first primary winding and the second primary winding meets |Lm1−Lm2|/(Lm1+Lm2)<=30%, Lm1 is the inductance of the first primary winding, and Lm2 is the inductance of the second primary winding.