Polyphase Converter with Planar Magnetic Coupling
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Solution Overview
Problem
Existing multiphase converters face challenges in reducing installation space, achieving simple manufacturability, and ensuring easy controllability while maintaining efficient magnetic coupling and insulation.
Innovation Solution
The design incorporates a two-dimensional phase structure with an insulating body and pre-assembled coupling means, allowing for precise positioning and easy assembly, using geometric shapes like U-shaped and meandering phases, and magnetic coupling with planar ferrite cores to minimize magnetic loading and reduce the size of coupling means.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If three-dimensional coupling structures are used to achieve magnetic coupling between phases, then magnetic coupling efficiency is improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent transitions from three-dimensional coupling structures to two-dimensional planar coupling structures. The coupling means are arranged in a plane with phases extending in opposite directions, eliminating the need for complex 3D spatial arrangements while maintaining magnetic coupling efficiency through planar magnetic circuits.
Solution Approach 2:
The patent uses identical or similar coupling means for different phase couplings, standardizing the coupling structure. Each coupling means has the same basic design with phases extending in opposite directions, simplifying manufacturing and assembly while ensuring consistent coupling performance across all phases.
2Reliability
If multiple coupling means are used to couple phases, then magnetic coupling is improved, but assembly complexity and time increase
Solution Approach 1:
The coupling means are pre-assembled with the phases in a modular configuration before final integration. The phases are attached to the coupling means in advance, creating pre-assembled units that simplify the overall assembly process and reduce on-site assembly time and complexity.
3Reliability
If insulation between phases is provided, then electrical isolation is improved, but device volume increases
Solution Approach 1:
The insulating body performs multiple functions simultaneously: it provides electrical insulation between phases, supports and positions the coupling means, and serves as a structural framework for the entire converter assembly. This integration of multiple functions into a single component eliminates the need for separate insulation elements, reducing overall volume.
Solution Approach 2:
The insulating body is designed as a multi-functional component that combines insulation, mechanical support, and structural functions. This universal component replaces what would otherwise require multiple separate parts, achieving electrical isolation without increasing device volume.
4Power
If conventional multiphase converter designs are used, then power conversion is achieved, but installation space and cost are excessive
Solution Approach 1:
The patent adopts a planar two-dimensional layout for all major components, including the insulating body, coupling means, and phases. This 2D arrangement eliminates the need for vertical stacking or complex 3D spatial arrangements, significantly reducing the footprint and installation space while maintaining full power conversion capability.
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 a cost-effective, compact multiphase converter with reduced assembly effort, enhanced reliability, and simplified control of current curves, minimizing magnetic fields and allowing for independent phase control, while also reducing power loss and heat generation.
Implementation Method 1
at least one phase is magnetically coupled to at least three other phases
Implementation Method 2
at least one insulating body is provided, which accommodates the phases to be coupled on its upper side or underside
Data Source
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AI summary
Polyphase converter, comprising a plurality of electrical phases (11 to 16), which can each be driven by switching means (21 to 26), wherein at least one coupling means (31 to 39) is provided, which magnetically couples at least one first phase (11) to at least one further phase (12, 14, 16), wherein at least two phases (11, 12) to be coupled are surrounded at least partially by the coupling means (31), wherein at least one insulating body (72) is provided, which on the upper or lower side thereof accommodates the phases (11 to 16) to be coupled and on which at least one fastening means (74, 76, 90) is provided, which interacts with at least one of the phases (11 to 16) for fastening purposes.