Planar Magnetic Component With Controlled Leakage Path for LCL-T Converters
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Solution Overview
Problem
Conventional planar magnetic designs for transformers fail to integrate controllable leakage inductance due to the absence of a first-order leakage path, limiting their effectiveness in high-frequency applications.
Innovation Solution
A magnetic component for a galvanically isolated LCL-T resonant converter is designed with unequal primary and secondary turns distributed around outer posts and a center post, which acts as a leakage path, allowing for controlled integration of leakage inductance by adjusting air gaps and turns distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional planar magnetic design with E+I core and interleaved windings is used, then automated manufacturing and thermal performance are improved, but controllable leakage inductance integration is lost due to absence of first order leakage path
Solution Approach 1:
The magnetic core is segmented into multiple separate cores (first core with outer posts and center post, second core) that are positioned adjacent to each other with controlled air gaps. This segmentation creates distinct magnetic paths, including a first-order leakage path through the air gap between center posts, enabling controllable leakage inductance while preserving planar manufacturing advantages
Solution Approach 2:
An air gap is introduced as an intermediary element between the center post of the first core and the second core. This air gap serves as a controlled magnetic reluctance path that enables leakage flux to flow independently from the main transformer flux, providing controllable leakage inductance without affecting the core interleaved winding structure
2Adaptability or versatility
If unequal primary and secondary turns are distributed around outer posts, then controllable leakage inductance is achieved, but winding distribution complexity increases
Solution Approach 1:
The winding distribution is optimized locally at each outer post to achieve the desired leakage inductance. By distributing primary and secondary turns unequally around the outer posts (with specific turn ratios), the design creates controlled local magnetic coupling that generates the required leakage flux path while maintaining overall system functionality
Solution Approach 2:
The magnetic component employs asymmetric winding distribution where the number of primary turns and secondary turns around each outer post are deliberately made unequal. This asymmetry creates an imbalance in magnetic coupling that generates the first-order leakage path through the air gap, enabling controllable leakage inductance integration
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 design effectively integrates a controllable leakage inductance, optimizing both core and winding losses, and enhancing the efficiency of high-frequency transformers in resonant converters.
Implementation Method 1
The first and second primary turns, the first and second secondary turns, and the first air gap are used to control and integrate a controllable leakage inductance, wherein the center post is used as a leakage path
Implementation Method 2
The center post of the first core and the second core are separated by a first air gap. The first and second primary turns, the first and second secondary turns, and the first air gap are used to control and integrate a controllable leakage inductance
Data Source
AI summary
A magnetic component for a galvanically isolated LCL-T resonant converter is provided. The magnetic component includes first and second cores, a primary winding and a secondary winding. The first core includes a first outer post, a second outer post, and a center post. The primary winding has primary turns including first primary turns located around the first outer post and second primary turns located around the second outer post. The secondary winding has secondary turns including first secondary turns located around the first outer post and second secondary turns located around the second outer post. The center post of the first core and the second core are separated by a first air gap. The turns distribution and the first air gap are used to control and integrate a controllable leakage inductance, where the center post is used as a leakage path.