Rectification Module Stacked Conducting Plates AC Impedance

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Solution Overview

Problem

High-frequency alternating current in synchronous rectification modules leads to significant AC conduction power loss due to skin and proximity effects, resulting in inefficiency and thermal issues, particularly in high-power and large-current applications.

Innovation Solution

The rectification module design includes a transformer with a connecting unit where conducting plates are stacked on each other, reducing AC impedance and enhancing efficiency by optimizing the layout and structure of the connecting unit to minimize power loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of energy

If conventional connecting unit structure is used, then device complexity is reduced, but AC conduction power loss increases due to skin effect and proximity effect

Engineering Contradiction:

ImproveAC conduction power lossVSAvoidconnecting unit structure

Core Design Contradiction:

Loss of energyVSDevice complexity

Solution Approach 1:

The patent transitions from a planar connecting unit layout to a three-dimensional stacked configuration. Multiple conducting plates are arranged in vertical layers rather than horizontal planes, utilizing the third dimension to reduce the effective current path length and minimize skin and proximity effects, thereby reducing AC conduction power loss.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The connecting unit is divided into multiple separate conducting plates stacked in layers, with each plate handling specific current paths. This segmentation allows for optimized current distribution across multiple isolated conductive surfaces, reducing the impact of skin and proximity effects compared to a single large-plane configuration.

Inventive Principle:

Principle #1Segmentation

2Reliability

If conducting plates are stacked on each other, then AC impedance is decreased, but device complexity increases

Engineering Contradiction:

ImproveefficiencyVSAvoidconnecting unit structure

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

Multiple conducting plates are merged into a compact stacked assembly that functions as an integrated connecting unit. The plates are positioned in close proximity with optimized spacing, combining their individual functions into a unified structure that achieves low AC impedance while maintaining a space-efficient design.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conducting plates are nested in a stacked configuration where each plate is positioned within the vertical space occupied by the overall connecting unit structure. This nesting approach allows multiple conductive elements to occupy minimal horizontal space while maintaining their individual electrical functions and achieving low AC impedance.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 reduces power loss and enhances efficiency by decreasing AC impedance, resulting in a more compact and high-power density rectification module.

Implementation Method 1

Since current through the rectification module is high frequency alternating current, for high power and current application, there will be significant AC conduction power loss due to skin effect and proximity effect

Methodology Applied

Scientific EffectSkin effect: Skin Effect

Implementation Method 2

Methodology Applied

Scientific EffectProximity effect:

Data Source

PatentUS10389266B2Rectification module

Publication Date: 2019.08.20 DELTA ELECTRONICS (THAILAND) PUBLIC CO LTD

AI summary

A rectification module includes a transformer, a connecting unit and a rectification unit. The transformer includes a first lateral region, a second lateral region and at least one secondary winding assembly. The second lateral region is located beside the first lateral region. The secondary winding assembly includes plural outlet ends. The plural outlet ends are arranged near the first lateral region. The connecting unit is located at the first lateral region, and includes plural conducting plates. Each of the conducting plates includes at least one opening and at least one connecting structure. The conducting plates are partially or completely stacked on each other. The outlet ends are accommodated within the corresponding openings. The conducting plates are fixed on the first lateral region. The connecting structures face the second lateral region. The rectification unit includes a circuit board and plural rectifier components.