Planar Transformer With Segmented Through Sections
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Solution Overview
Problem
Conventional DC/DC converters experience efficiency drops due to increased conductor resistance and heat generation, leading to a vicious cycle of loss increase and reduced efficiency.
Innovation Solution
A DC/DC converter design with an inverter circuit connected to a primary coil group and a rectification/smoothing circuit connected to a secondary coil group, featuring a transformer core with separate through sections for improved heat radiation and magnetic coupling of coils to enhance cooling efficiency and uniform current distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional transformer windings are used, then the structure is simple, but conductor resistance increases and heat loss increases, leading to efficiency drop
Solution Approach 1:
The transformer core is divided into multiple separate through sections (first through section and second through section) that are spatially separated. Coils are distributed across these sections rather than concentrated in one location, segmenting the magnetic circuit and current paths to reduce resistance and improve heat dissipation.
Solution Approach 2:
The patent transitions from conventional planar windings to a three-dimensional spatial arrangement where coils are distributed across multiple through sections of the core. This dimensional redistribution allows for shorter conductor paths and better thermal management while maintaining magnetic coupling.
2Temperature
If coils are concentrated in one through section, then the structure is compact, but heat radiation is poor and cooling efficiency is low
Solution Approach 1:
The transformer is segmented into multiple through sections with coils distributed across them. This spatial segmentation increases the surface area exposed to cooling environments and prevents heat concentration in a single location, improving overall heat radiation efficiency.
Solution Approach 2:
Different through sections are positioned to optimize local heat dissipation characteristics. The spatial separation allows each coil group to have its own thermal management zone, improving local cooling efficiency while maintaining compact overall dimensions.
3Stability of the object's composition
If conventional winding arrangements are used, then manufacturing is simple, but current distribution is non-uniform and output ringing occurs
Solution Approach 1:
The coil group is segmented into multiple sub-groups distributed across different through sections. This segmentation creates more uniform current distribution by reducing eddy current effects and improving magnetic flux uniformity, while the modular structure facilitates manufacturing.
Solution Approach 2:
The magnetic core acts as an intermediary that couples the distributed coil groups. The core's magnetic path ensures uniform flux distribution across all coil sections, stabilizing current distribution and suppressing output ringing through improved magnetic coupling.
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 design improves cooling efficiency and power conversion efficiency by reducing AC resistance and suppressing output ringing, resulting in higher performance and stability of the DC/DC converter.
Implementation Method 1
a transformer (40) which has a primary coil group (42, 43) and a secondary coil group (45, 46), wherein the transformer (40) includes a core (41) which comprises a first through section (41X) and a second through section (41Y) that are spatially separate from each other and constitute a magnetic circuit together with the first through section (41X)
Implementation Method 2
the first through section (41X) passes through the inside of at least one coil of the primary coil group (42, 43) and at least one coil of the secondary coil group (45, 46); the second through section (41Y) passes through the inside of the remaining coils of the primary and secondary coil groups
Data Source
Figure 1
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Figure 3
AI summary
A DC/DC converter comprises a transformer (4) in which primary and secondary coils are provided in the first through section (41A1 and 41B1) and a coil group is also provided in the second through section (41A2 and 41B2). Hence, the surface area over which the coil group extends within a plane which is perpendicular to the through sections is greater than in the case where all of the coils are provided in a single through section. The surface area which is not covered by the magnetic body cores of the platelike members (SP1,SP2) increases. In cases where the surface area of the members is large, the heat radiation characteristic is enhanced. Hence, the cooling efficiency of the transformer improves. In cases where there is a plurality of coil groups which are magnetically coupled to one another in particular, because it is difficult to move the heat produced in the plurality of coil groups through heat conduction, heat transfer, or heat radiation, a heat radiation structure of this kind is effective.