Planar Transformer DC/DC Converter for High Power Density
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Solution Overview
Problem
Conventional DC/DC converters have low power density, low reliability, high assembly costs, and complex mechanical structures, which are not suitable for high-efficiency applications like hybrid electric vehicles.
Innovation Solution
A DC/DC converter design with a simplified winding structure, reduced rectifier switch numbers, higher switching frequency, and a planar transformer for improved power density and efficiency, along with reduced ripple current and parasitic loads, using MOSFETs or IGBTs and a control circuit for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional DC/DC converter design with discrete devices is used, then the converter can be assembled, but it results in low power density, low reliability, and high assembly cost
Solution Approach 1:
The patent merges multiple discrete components (transformer, inductors, capacitors, rectifier switches) into an integrated planar module with unified magnetic core structure. The planar transformer and inductors share the same magnetic core and winding structure, eliminating the need for separate mechanical assemblies and improving reliability while reducing complexity.
Solution Approach 2:
The planar magnetic core structure serves multiple functions simultaneously: it acts as the transformer core, provides inductance for the inductors, and integrates the magnetic paths for both high-voltage and low-voltage sides. This multi-functionality reduces the number of separate components needed and simplifies the overall mechanical structure.
2Power
If conventional DC/DC converter design is used, then the converter can operate, but it results in low power density
Solution Approach 1:
The patent transitions from traditional three-dimensional stacked component arrangement to a planar two-dimensional layout. The planar transformer and inductors are arranged on the same magnetic core plane, allowing more efficient space utilization and higher power density within the same volume footprint.
Solution Approach 2:
The patent implements nesting by placing the low-voltage inductors within the magnetic core structure of the high-voltage transformer. The planar magnetic core provides nested magnetic paths that allow multiple inductive elements to occupy overlapping spatial regions, maximizing power density.
3Ease of manufacture
If conventional DC/DC converter design is used, then the converter can be assembled, but it results in high assembly cost
Solution Approach 1:
The patent combines the transformer windings and inductor windings into a single integrated winding structure on the planar magnetic core. This unified winding structure can be manufactured as one piece using automated winding machines, significantly reducing assembly cost compared to manually assembling separate transformer and inductor windings.
Solution Approach 2:
The patent changes the winding structure from traditional multi-layer three-dimensional windings to planar single-layer windings on a flat magnetic core. This parameter change simplifies the winding process and enables automated manufacturing, reducing assembly cost while maintaining the required electrical performance.
4Device complexity
If reduced rectifier switch numbers are used, then the device count is reduced, but current sharing and operating temperature must be optimized
Solution Approach 1:
The patent applies local quality by using synchronized rectification control that optimizes the operating conditions of each rectifier switch based on its specific position and current load. This localized control ensures optimal current sharing and temperature distribution even with reduced switch count, preventing thermal runaway in high-current switches.
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 achieves high power density, reliability, reduced EMI, and lower operating temperatures, with improved durability and efficiency, and reduced lot-to-lot variation, resulting in a cost-effective and efficient power conversion system.
Implementation Method 1
a transformer inductively coupling the high and low voltage sides
Data Source
AI summary
Power converter system topologies comprise a DC/DC converter. The DC/DC converter includes a transformer coupling a high side to a low side. The high side may include an inverter bridge in the form of an inverter module and an inductor. The low side may include a rectifier in the form of a rectifier module and a pair of inductors. The transformer may take the form of a planar transformer.