Power Conversion Module Layout for Low Ripple and High Power Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional power conversion modules with single-stage conversion structures face challenges such as large size, high power loss, significant AC current ripple, and low magnetic saturation capability, making them unsuitable for long-sized and high-density electronic devices.
Innovation Solution
A power conversion module design featuring a magnetic device with specific magnetic leg resistance configurations and winding arrangements, where the magnetic resistance of the second and fourth magnetic legs is greater than the first and third, and the projections of the windings are partially overlapped, reducing AC current ripple and enhancing magnetic saturation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the conventional power conversion module uses a single-stage conversion structure, then the power conversion efficiency is improved, but the size of the module becomes large
Solution Approach 1:
The magnetic device is divided into multiple magnetic legs (first, second, third, and fourth magnetic legs) with different magnetic resistance characteristics. The second and fourth magnetic legs have greater magnetic resistance than the first and third magnetic legs, creating an asymmetric segmented structure that optimizes both efficiency and size
Solution Approach 2:
Different magnetic legs are assigned different magnetic resistance values to perform different functions. The higher magnetic resistance in the second and fourth legs helps reduce AC current ripple, while the overall compact arrangement reduces module size while maintaining single-stage conversion efficiency
2Ease of manufacture
If the magnetic device uses conventional structure and winding method, then the manufacturing is simplified, but the power loss becomes large
Solution Approach 1:
The magnetic device employs an asymmetric structure where the second and fourth magnetic legs have greater magnetic resistance than the first and third magnetic legs. This asymmetric design optimizes power loss characteristics while maintaining manufacturability through standardized magnetic core components
Solution Approach 2:
The windings are arranged with partial overlap in the projection direction, utilizing spatial arrangement in multiple dimensions. This overlapping projection configuration reduces power loss by optimizing magnetic flux distribution without complicating the winding manufacturing process
3Device complexity
If the magnetic device uses conventional winding arrangement, then the device complexity is reduced, but the AC current ripple becomes large
Solution Approach 1:
The asymmetric magnetic resistance distribution among the four magnetic legs (with second and fourth legs having greater resistance) creates balanced magnetic flux paths that reduce AC current ripple without requiring complex winding arrangements
Solution Approach 2:
The windings are positioned such that their projections partially overlap in the spatial arrangement. This dimensional optimization of winding layout reduces AC current ripple by improving magnetic coupling while maintaining simple winding structures
4Ease of manufacture
If the magnetic device uses conventional structure, then the manufacturing cost is reduced, but the capability of withstanding magnetic saturation becomes low
Solution Approach 1:
The asymmetric magnetic resistance design with higher resistance in the second and fourth magnetic legs improves magnetic saturation capability by optimizing flux distribution across the magnetic core, while still using conventional magnetic materials and manufacturing techniques
Solution Approach 2:
Different magnetic legs are designed with different magnetic resistance values to locally optimize magnetic flux distribution. This local differentiation enhances overall magnetic saturation capability without requiring expensive specialized materials or complex manufacturing processes
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 results in a compact, high-power-density module with reduced AC current ripple and improved magnetic saturation capability, suitable for applications in long-sized and high-density electronic devices like display cards or ASIC cards.
Implementation Method 1
a magnetic device, a primary switch circuit, a first secondary rectifying circuit
Data Source
AI summary
A power conversion module is disclosed. The power conversion module includes a power conversion module includes a circuit board and a first basic power unit. The first basic power unit is disposed on the circuit board and includes a magnetic device, a primary switch circuit, a first secondary rectifying circuit and a first positive output terminal pin. The primary switch circuit, the first secondary rectifying circuit, the magnetic device and the first positive output terminal pin are sequentially arranged on the circuit board along a first direction.