Rake-Core Transformer Assembly for Higher Power Density Cooling
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Solution Overview
Problem
Conventional transformer assemblies in electric conversion devices have low power density due to the large number of magnetic components, leading to increased volume and temperature issues, as they often require multiple magnetic cores for transformers and chokes, resulting in inefficient cooling and high hot-spot temperatures.
Innovation Solution
A transformer assembly with rake-shaped core members, featuring interconnected winding legs and return legs, allows for the integration of multiple transformers or chokes into a single-phase configuration by electrically connecting winding pairs in series, enhancing power density and cooling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple magnetic cores are used for transformers and chokes in conventional configurations, then the device can perform multiple functions, but the total volume of magnetic components increases significantly
Solution Approach 1:
The patent merges multiple magnetic cores into a single integrated magnetic component structure. The core design combines transformer windings and choke windings on shared magnetic paths, eliminating the need for separate magnetic cores for each component. This integration directly reduces the total volume of magnetic materials while maintaining the functional independence of transformers and chokes.
Solution Approach 2:
The integrated magnetic component serves multiple functions simultaneously - it acts as both transformer and choke for different phase combinations. The magnetic core structure is designed to support multiple winding configurations that can function as single-phase or three-phase transformers, and as PFC chokes, all within a single unified component.
2Ease of manufacture
If multiple separate magnetic cores are used, then each component can be independently designed, but the number of cooling surfaces decreases
Solution Approach 1:
The patent combines multiple magnetic cores into a single integrated structure that provides unified thermal management. This merged design creates larger continuous cooling surfaces compared to multiple separate small cores, enabling more effective heat dissipation. The integrated structure allows cooling channels or surfaces to serve the entire assembly rather than requiring separate cooling paths for each component.
3Ease of manufacture
If multiple separate magnetic cores are used, then component independence is maintained, but power density decreases
Solution Approach 1:
The patent merges multiple magnetic cores into a single integrated magnetic component structure. The core design combines transformer windings and choke windings on shared magnetic paths, eliminating the need for separate magnetic cores for each component. This integration directly reduces the total volume of magnetic materials while maintaining the functional independence of transformers and chokes.
Solution Approach 2:
The integrated magnetic component serves multiple functions simultaneously - it acts as both transformer and choke for different phase combinations. The magnetic core structure is designed to support multiple winding configurations that can function as single-phase or three-phase transformers, and as PFC chokes, all within a single unified component.
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 significantly reduces the volume of magnetic components, improves power density, and facilitates efficient cooling, thereby mitigating temperature issues and enhancing the overall performance of electric conversion devices.
Implementation Method 1
each of the at least three winding legs is wounded by at least one electrical winding. The at least three winding legs and the at least two return legs are connected magnetically to the body portion
Implementation Method 2
at least a first winding leg and at least a second winding leg form at least one winding leg pair, and at least a first electrical winding of the first winding leg is electrically connected in series with at least a second electrical winding of the second winding leg
Data Source
AI summary
The present application concerns a transformer assembly, especially for an electric conversion device, including at least one rake-shaped core member each of the at least one rake-shaped core member including a body portion, at least three winding legs, and at least two return legs, wherein each of the at least three winding legs is wounded by at least one electrical winding and the at least three winding legs and the at least two return legs being connected magnetically to the body portion; wherein at least a first winding leg and at least a second winding leg form at least one winding leg pair, and at least a first electrical winding of the first winding leg is electrically connected in series with at least a second electrical winding. The present application also concerns an electric conversion device including at least one transformer assembly.