Planar Core Inductive Subassembly with Air Gap
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Solution Overview
Problem
Existing inductive electronic assemblies for resonant converter topologies require additional components and space to implement series or resonance inductance on the primary side, which compromises the compactness and efficiency of the arrangement.
Innovation Solution
The design incorporates a pair of planar core elements with an air gap between the inner limbs to realize series or resonant inductance without increasing the geometry or adding discrete components, allowing the existing dimensions to be maintained while enabling efficient energy storage and preventing magnetic saturation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If additional discrete components or assemblies are added to implement series or resonance inductance on the primary side, then the resonant converter topology can be realized, but the compactness and efficiency of the arrangement deteriorates
Solution Approach 1:
The patent merges the series or resonance inductance function with the existing planar core element structure by incorporating it into the primary winding arrangement. The inductance is realized through the magnetic circuit of the core element itself, eliminating the need for separate discrete inductance components and maintaining compactness.
Solution Approach 2:
The planar core element is designed to serve multiple functions: it provides magnetic coupling for the transformer arrangement and simultaneously provides the series or resonance inductance for the resonant converter topology through its magnetic circuit path. This multi-functionality eliminates the need for dedicated separate components.
2Adaptability or versatility
If the geometry of the planar core element is increased to accommodate additional inductance, then series or resonance inductance can be implemented, but the compact design and existing dimensions are compromised
Solution Approach 1:
The patent utilizes the planar (two-dimensional) structure of the core element to accommodate the inductance function without increasing the overall volume. The magnetic circuit path for the series or resonance inductance is arranged within the existing planar geometry, leveraging the surface area rather than expanding into additional spatial dimensions.
3Adaptability or versatility
If additional side limbs are provided to accommodate additional inductance, then resonant converter topology can be realized, but the compactness of the arrangement deteriorates
Solution Approach 1:
The patent segments the magnetic circuit path within the existing core element structure to create distinct functional regions. The series or resonance inductance is realized through a specific magnetic path segment within the primary winding arrangement, allowing the inductance function to be separated from the transformer coupling function while using the same physical structure.
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 allows for the implementation of resonant converters with additional inductance within the existing dimensions, maintaining magnetic decoupling and efficiency without the need for additional components or side limbs, thus enhancing the assembly's compactness and mass production advantages.
Implementation Method 1
the opposing second core sections of the pair of planar core elements to implement an air gap ensures that the series or resonant inductance formed thereon can properly fulfill its task as an energy store and that no magnetic saturation effects can Affect the primary side of the input transformer
Implementation Method 2
the respective winding arrangements that implement the transformers to interact with the inner limb or the side limbs
Data Source
Figure 1~3
Figure 4~7
AI summary
The inductive electronic module has a planar core element having inner limbs (29a,55a) comprising lateral limbs (33a,35a,37a,39a) on either sides. The inner limb has a primary core section that is arranged for interacting with planar primary winding arrangement (TR1-A), and secondary core section that is provided spaced from primary core section and is arranged for interacting with an additional planar winding arrangement (C1). The secondary core section is arranged for implementing magnetically active air gap for additional planar winding arrangement.