Power Module Integrating Transformer and Rectifier to Reduce Leakage Inductance
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Solution Overview
Problem
Conventional power supply units experience high power loss due to long current paths and increased leakage inductance, which deteriorate reliability and efficiency, and have complex assembly processes.
Innovation Solution
A power module with a circuit board assembly that includes a primary winding coil, a secondary winding structure, current-sensing elements, and a rectifier circuit, where the secondary winding structure and current-sensing elements are aligned within a magnetic core assembly to minimize current path length and leakage inductance, and are electrically connected to a system board through an electrical connector.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the transformer, rectifier and current transformer are mounted on the system board with long current paths, then the electrical connection is established, but high power loss occurs at the welded sections and current path
Solution Approach 1:
The patent combines the transformer, rectifier, and current transformer into a single integrated power module. The secondary winding coil is directly connected to the rectifier circuit and current transformer within the same module, eliminating the need for long current paths through the system board. This merging of components directly reduces power loss while maintaining reliable electrical connections.
2Reliability
If the current transformer generates increased leakage inductance, then the current sensing function is provided, but additional power loss occurs
Solution Approach 1:
The current transformer is integrated within the power module, with its conductive wire directly connected to the secondary winding coil and rectifier circuit. This close integration minimizes the loop area and reduces leakage inductance, allowing the current sensing function to operate with minimal additional power loss.
3Reliability
If the transformer pins are welded on the system board with long distance to rectifier, then the electrical connection is established, but the assembly process becomes complicated
Solution Approach 1:
The patent integrates the transformer, rectifier, and current transformer into a single power module with internal connections. This eliminates the need for separate welding of transformer pins to the system board and reduces the number of assembly steps, simplifying the overall assembly process while maintaining reliable electrical connections.
Solution Approach 2:
The power module is pre-assembled with all internal connections (secondary winding coil to rectifier, current transformer connections) established before mounting to the system board. This preliminary assembly of critical components reduces on-site assembly complexity and ensures reliable connections are made under controlled conditions.
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 reduces power loss by shortening the current path and minimizing leakage inductance, thereby enhancing the reliability and efficiency of the power module while simplifying the assembly process.
Implementation Method 1
The primary winding coil is wound around the first bobbin... The second winding structure is aligned with the primary winding coil, and arranged within the first magnetic core assembly
Implementation Method 2
The first magnetic core assembly includes a first magnetic part and a second magnetic part... The second winding structure is aligned with the primary winding coil, and arranged within the first magnetic core assembly
Data Source
AI summary
A power module mounted on a system board comprises a printed circuit board having an extension part, at least one primary winding coil disposed on a first side of the extension part. The at least one primary winding coil is disposed at a primary side of the power module. The power module further comprises a PCB winding formed on the extension part at a secondary side of the power module, a first magnetic core assembly, and a connector. The first magnetic core assembly comprises a first magnetic part and a second magnetic part. The at least one primary winding coil and the extension part are enclosed between the first magnetic part and the second magnetic part.