Planar Transformer Magnetic Core With Multiple Materials
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Solution Overview
Problem
Planar transformers in power conversion circuits face significant winding losses due to core saturation and magnetic flux leakage, particularly when using single magnetic materials with high permeability, which affects efficiency and size constraints in electronic devices.
Innovation Solution
The use of multiple magnetic materials with varying permeabilities in different sections of the magnetic cores, eliminating air gaps and forming a complete magnetic circuit, reduces winding losses by preventing core saturation and maintaining overall permeability, thereby enhancing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If high permeability magnetic material is used in the core, then magnetic flux density is improved, but core saturation occurs leading to increased winding losses
Solution Approach 1:
The magnetic core is divided into different regions with different magnetic material properties. The first magnetic material with higher permeability is used in regions requiring strong magnetic flux concentration, while the second magnetic material with lower permeability is used in regions prone to saturation. This local differentiation allows each region to operate optimally without causing overall core saturation, thereby reducing winding losses while maintaining reliability.
Solution Approach 2:
The patent employs a composite magnetic core structure combining two different magnetic materials with distinct permeability characteristics. This composite approach enables the core to simultaneously achieve high magnetic flux density in critical areas while maintaining sufficient saturation margin in other areas, effectively preventing core saturation and reducing winding losses without sacrificing magnetic performance.
2Loss of energy
If air gaps are present in the magnetic core, then magnetic flux leakage is reduced, but magnetic circuit completeness is compromised affecting efficiency
Solution Approach 1:
The patent modifies the magnetic path parameters by eliminating air gaps and replacing them with magnetic materials of appropriate permeability. This parameter change maintains the continuity and completeness of the magnetic circuit, ensuring efficient magnetic flux transmission while minimizing flux leakage through proper material selection and structural design.
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 approach results in reduced winding losses and improved efficiency in power conversion circuits, with specific configurations like (2,1,1,2) achieving a 65% efficiency improvement in power converters by minimizing magnetic flux leakage and core saturation.
Implementation Method 1
the first magnetic material has different properties than the second magnetic material
Implementation Method 2
core saturation
Implementation Method 3
magnetic flux leakage
Implementation Method 4
transform one form of electrical energy to another
Data Source
AI summary
Systems and methods for improving winding losses in transformers are disclosed. In one aspect, a transformer includes a first magnetic core having an interior portion and an exterior portion, a second magnetic core in contact with the interior and exterior portions, a plurality of primary and secondary windings formed around the interior portion, where the interior portion is formed from one of a first magnetic material and a second magnetic material, and the exterior portion is formed from one of the first magnetic material and the second magnetic material, where the first magnetic material has different properties than the second magnetic material. In another aspect, the first magnetic core includes a third portion that extends across and is in contact with the interior portion and the exterior portion, where the third portion is formed from one of the first magnetic material and the second magnetic material.