Segmented Magnetic Core for Power Conversion Inductance
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Solution Overview
Problem
Existing power conversion devices face challenges in achieving accurate inductance settings for both normal-mode and common-mode noise reduction, leading to increased size and induction heating issues due to leakage fluxes, making it difficult to miniaturize the devices while maintaining performance.
Innovation Solution
A power conversion device design featuring a core with multiple leg portions and conductive members with windings arranged to distribute core gaps, reducing leakage fluxes and eddy current losses, allowing for precise inductance adjustment and miniaturization by using soft magnetic materials and non-magnetic gap members.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a long core gap is provided to achieve desired normal-mode inductance and common-mode inductance, then inductance accuracy is improved, but induction heating of the winding increases due to leakage fluxes
Solution Approach 1:
The core gap is divided into multiple segments (first core gap and second core gap) distributed across different leg portions of the core. This segmentation reduces the concentration of leakage fluxes in a single location, thereby reducing induction heating in the winding while still achieving the desired inductance accuracy through the combined effect of multiple gaps.
Solution Approach 2:
Different leg portions of the core are assigned different gap configurations (first leg portion has first core gap, second and third leg portions have second core gaps). This local differentiation allows optimization of flux distribution to reduce induction heating in specific winding regions while maintaining overall inductance performance.
2Measurement precision
If a long core gap is provided to achieve desired inductance values, then inductance setting is improved, but coil size increases due to heating effects
Solution Approach 1:
The core gap is segmented into multiple smaller gaps distributed across different core sections. This reduces the total leakage flux concentration and associated heating in any single region, allowing the coil to maintain a compact size without excessive thermal expansion or insulation requirements that would result from a single long gap.
Solution Approach 2:
The leakage fluxes that would normally cause harmful induction heating are redistributed through multiple smaller gaps, converting the harmful concentrated effect into a beneficial distributed effect that reduces peak heating while maintaining the necessary inductance characteristics.
3Volume of moving object
If switching frequency is increased to reduce reactor size, then device size is reduced, but normal-mode inductance decreases
Solution Approach 1:
The reactor core incorporates multiple segmented gaps that allow for optimized magnetic flux paths at higher switching frequencies. This segmentation enables the reactor to maintain adequate normal-mode inductance despite the reduced physical size, as the distributed gaps create more effective flux confinement in a compact geometry.
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 effectively reduces induction heating and coil size while achieving high accuracy in inductance settings for both normal-mode and common-mode noise reduction, enabling smaller and more efficient power conversion devices.
Implementation Method 1
a first core member composed of a soft magnetic material and provided with a plurality of gaps
Implementation Method 2
a plurality of first gap members each composed of a non-magnetic body and arranged in respective ones of the plurality of gaps in the first core member
Implementation Method 3
a first winding wound around the first leg portion and a second winding connected in series to the first winding and wound around the second leg portion
Implementation Method 4
Linkage of magnetic fluxes that leak from a core gap with a wound coil causes eddy current loss in the coil
Data Source
AI summary
A first leg portion is arranged between a second leg portion and a third leg portion. A first conductive member includes a first winding wound around the first leg portion and a second winding connected in series to the first winding and wound around the second leg portion. A second conductive member includes a third winding wound around the first leg portion and a fourth winding connected in series to the third winding and wound around the third leg portion. The first leg portion includes a first core member provided with a plurality of gaps and constituted of core pieces and a plurality of first gap members each made of a non-magnetic body and arranged in respective ones of the plurality of gaps in the first core member. Thus, influence by induction heating of the winding can be lessened and a coil can be reduced in size.