Power Converter Magnetic Core Layout for Uniform Cooling
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Solution Overview
Problem
In switching power supplies, the second magnetic core is inadequately cooled compared to the first core, leading to increased losses and reduced power conversion efficiency.
Innovation Solution
A power converter design that thermally connects both magnetic cores to a housing with varying thermal conductance portions, ensuring both cores are effectively cooled and reducing temperature differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the second magnetic core is disposed on the side distant from the heat dissipation plate, then the magnetic component structure is simplified, but the cooling effectiveness of the second core deteriorates
Solution Approach 1:
The patent transitions from a single-plane stacking arrangement to a three-dimensional spatial configuration where magnetic cores are positioned at different locations relative to the heat dissipation plate. The first magnetic core is disposed on the heat dissipation plate while the second magnetic core is positioned at a different spatial location, both maintaining thermal connection to the plate through varied geometric arrangements, thus achieving effective cooling for all cores without simplified single-plane stacking.
2Device complexity
If the second magnetic core is disposed on the side distant from the heat dissipation plate, then the assembly layout is simplified, but the power conversion efficiency deteriorates due to increased losses
Solution Approach 1:
The patent employs three-dimensional spatial arrangement to position magnetic cores at optimized locations relative to the heat dissipation plate. The first magnetic core is disposed on the heat dissipation plate and the second magnetic core is positioned at a different spatial location, both maintaining effective thermal connection. This dimensional approach ensures adequate cooling for all magnetic cores, reducing energy losses and improving power conversion efficiency while achieving a compact assembly layout.
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 lowers the maximum temperature of the magnetic cores, reduces losses, and improves power conversion efficiency by ensuring uniform cooling of both magnetic cores.
Implementation Method 1
The first magnetic core member and the second magnetic core member are both thermally connected to the first portion
Data Source
AI summary
A power converter includes a circuit board, a first magnetic core, and a housing. The circuit board includes an insulating substrate and a first coil conductor. The insulating substrate includes a first side surface. The first magnetic core includes a first magnetic core member and a second magnetic core member. A first side surface of the insulating substrate is opposed to a first portion of the housing and is spaced away from the first portion of the housing. The first magnetic core member and the second magnetic core member are both thermally connected to the first portion.