Segmented Core Gap Structure for Low-Loss Magnetic Components
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Solution Overview
Problem
Conventional magnetic components for power converters suffer from high AC losses and low power density, along with inefficient cooling and costly manufacturing processes due to the linear inductance and complex assembly procedures.
Innovation Solution
A magnetic component design featuring a gap distribution device with magnetic pieces and a holding frame that distributes gaps between magnetic core surfaces, allowing for efficient cooling and reduced AC losses, achieved through a configuration that replaces legs of magnetic cores with the gap distribution device, which includes thermal paste and fringing field shielding for improved performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional air gap distribution methods are used, then inductance control is achieved, but AC losses increase and power density decreases
Solution Approach 1:
The air gap is segmented into multiple smaller gaps by inserting a plurality of ferrite plates (gap distribution device) between the magnetic core legs. This segmentation reduces AC copper losses by distributing the magnetic flux more evenly across the winding, while the ferrite plates maintain the magnetic circuit integrity. The segmentation allows for optimized winding placement and improved thermal management, thereby increasing power density despite the increased structural complexity.
2Temperature
If conventional cooling methods are used, then simple structure is maintained, but cooling efficiency is poor
Solution Approach 1:
The gap distribution device serves multiple functions simultaneously: it distributes the air gap to reduce AC losses, provides a structured framework for winding placement, and acts as a thermal management interface. The ferrite plates are positioned to facilitate heat dissipation from the winding to the magnetic core, which can be thermally coupled to heat sinks. This merging of functions improves cooling efficiency without proportionally increasing structural complexity.
3Ease of manufacture
If conventional manufacturing procedures are used, then traditional assembly methods are maintained, but manufacturing cost and complexity increase
Solution Approach 1:
The ferrite plates of the gap distribution device are pre-positioned and secured to the magnetic core legs before the winding is placed. This preliminary action creates a stable framework that guides the winding placement process, ensuring proper positioning and reducing assembly complexity. The pre-assembled gap distribution device allows for modular manufacturing, where the magnetic core assembly with integrated gap distribution can be produced as a separate module and then combined with the winding and other components, thereby improving overall manufacturing efficiency.
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 achieves low AC losses, high power density, and efficient cooling, simplifying manufacturing while maintaining effective magnetic characteristics, thereby enhancing the performance and efficiency of magnetic components in power converters.
Implementation Method 1
a gap distribution device comprising at least one magnetic piece and at least one holding frame configured to hold the at least one magnetic piece. The gap distribution device is arranged within said at least one gap of the at least one magnetic core such that the at least one magnetic piece is arranged within said gap.
Implementation Method 2
the magnetic component, especially the gap distribution device, can be efficiently cooled
Data Source
AI summary
The disclosure concerns a magnetic component comprising at least one magnetic core, wherein at least one gap is formed between surfaces, especially opposing end surface(s) and/or side surface(s), of the magnetic core(s), wherein a direction extending between said surfaces is defined as a gap extension direction, a gap distribution device comprising at least one magnetic piece and at least one holding frame configured to hold the at least one magnetic piece, wherein the gap distribution device is arranged within said at least one gap of the at least one magnetic core such that the at least one magnetic piece is arranged within said gap, and at least one electrical winding wound around the at least one magnetic core and/or the at least one holding frame of the gap distribution device.