Planar Magnetic Core Assembly for Fast-Response Power Conversion
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Solution Overview
Problem
Current power conversion modules with two-stage converters have low efficiency and limited applications, while single-stage converters with integrated magnetic elements achieve higher efficiency but have large output inductance, failing to meet dynamic property requirements for high power density and efficiency.
Innovation Solution
A magnetic device with a magnetic core assembly and a power conversion module that includes a transformer and inductor design with a unique winding structure and magnetic core configuration, reducing parasitic resistance and inductance, and utilizing a half-bridge current-doubling rectifier circuit to enhance conversion efficiency and dynamic response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a single-stage converter with integrated magnetic element is used, then conversion efficiency and power density are improved, but output inductance becomes large and dynamic properties deteriorate
Solution Approach 1:
The integrated magnetic element is segmented into separate magnetic cores for the transformer and output inductor. This allows independent optimization of each component's inductance and enables better dynamic response while maintaining high conversion efficiency through the single-stage converter architecture.
Solution Approach 2:
The magnetic legs are arranged in a planar configuration with specific geometric dimensions (first dimension: length of magnetic legs, second dimension: width of magnetic legs). This dimensional arrangement reduces parasitic resistance and optimizes the magnetic path, achieving both high efficiency and fast dynamic response.
2Power
If a single-stage converter with integrated magnetic element is used, then power density is improved, but output inductance becomes large
Solution Approach 1:
The magnetic element is divided into separate transformer and inductor components with distinct magnetic cores. This segmentation allows the output inductor to have smaller, optimized inductance value while the transformer handles the main power conversion, achieving high power density without excessive inductance.
Solution Approach 2:
The inductance parameters are independently optimized for each magnetic component. The transformer and output inductor have different inductance values tailored to their specific functions, enabling high power density while controlling the overall inductance to appropriate levels for fast dynamic response.
3Ease of manufacture
If conventional magnetic core configuration is used, then manufacturing is simplified, but parasitic resistance and inductance increase
Solution Approach 1:
The magnetic legs are arranged in a planar configuration with optimized dimensions (length and width parameters). This geometric arrangement reduces the length of current paths and minimizes parasitic resistance while maintaining manufacturing simplicity through standardized core shapes and configurations.
Solution Approach 2:
The magnetic device uses composite magnetic core structures with different material properties optimized for specific functions. The transformer and inductor portions may use different magnetic materials or configurations to minimize parasitic effects while maintaining ease of manufacture through modular assembly.
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 solution improves the efficiency and power density of the power conversion module, reducing inductance and parasitic resistance, thereby enhancing the dynamic response speed and reducing volume, while maintaining high conversion efficiency for high input voltages and low output voltages.
Implementation Method 1
a magnetic device which is an inductor or a combination of a transformer and an inductor
Data Source
AI summary
A magnetic device for a power conversion module is provided. The magnetic device includes a magnetic core assembly. The magnetic core assembly includes an upper magnetic cover, a lower magnetic cover, a first magnetic leg, a second magnetic leg and a channel. The lower magnetic cover includes a first opening and a second opening. The first magnetic leg is disposed between the upper magnetic cover and the lower magnetic cover. The second magnetic leg is disposed between the upper magnetic cover and the lower magnetic cover. The channel is disposed between the first magnetic leg and the second magnetic leg. When the upper magnetic cover and the lower magnetic cover are locked on a circuit board, the first magnetic leg and the second magnetic leg are included in a projection region of the upper magnetic cover with respect to the lower magnetic cover.