Segmented Path Core Transformer for Lower Eddy Current Loss
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Solution Overview
Problem
Existing transformers suffer from eddy current losses due to leakage magnetic flux crossing the primary and secondary windings, which is not effectively addressed by existing designs.
Innovation Solution
A transformer design with a core and path core configuration that includes gaps and segments to minimize the distance of leakage magnetic flux from the windings, utilizing adhesion layers to fix segments to protruding portions for further reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a path core is provided between primary and secondary windings to guide leakage magnetic flux, then magnetic flux is contained within a defined path, but the leakage magnetic flux still passes closer to the windings than to the path core extension, causing eddy current losses
Solution Approach 1:
The path core is divided into multiple segments along the magnetic flux path. By segmenting the path core, the invention creates multiple gap regions that force the leakage magnetic flux to take a path farther from the windings, thereby reducing eddy current losses without requiring complete redesign of the core structure
Solution Approach 2:
Gap regions are introduced as intermediary elements between the path core segments. These gaps act as mediators that redirect the leakage magnetic flux away from the windings, effectively reducing eddy current losses while maintaining the overall core structure
2Loss of energy
If gaps are formed in the path core to redirect leakage magnetic flux away from windings, then eddy current losses are reduced, but manufacturing precision requirements increase
Solution Approach 1:
The path core is segmented into multiple sections with gaps between them. This segmentation approach allows the gaps to be formed as discrete features rather than requiring precise continuous positioning, thereby reducing manufacturing precision requirements while still achieving the goal of redirecting leakage magnetic flux
Solution Approach 2:
Instead of requiring a single precisely positioned gap, the invention uses multiple gaps with potentially varied dimensions. This partial action approach provides manufacturing tolerance, as the exact position and size of individual gaps are less critical when multiple gaps work together to redirect the magnetic flux
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
Reduces eddy current losses by minimizing the magnetic flux density crossing the windings, achieving lower eddy current losses compared to traditional designs.
Implementation Method 1
a path core that forms, together with the core, a magnetic path through which leakage magnetic flux passes
Implementation Method 2
Since magnetic flux passes through a path of least magnetic reluctance, the leakage magnetic flux passes closer to each winding than to an extension of the path core
Implementation Method 3
the leakage magnetic flux crosses each winding, which may generate eddy current losses
Data Source
AI summary
A transformer includes a core having a center leg portion extending in a first direction and a side leg portion provided away from the center leg portion in a second direction that intersects with the first direction, a primary winding wound around the center leg portion, a secondary winding provided apart from the primary winding in the first direction and wound around the center leg portion, and a path core that forms, together with the core, a magnetic path through which leakage magnetic flux passes, the path core extending in the second direction and being provided between the primary winding and the secondary winding. The path core is disposed so that a plurality of gaps is formed in a section that extends from the center leg portion to the side leg portion through the path core in the magnetic path.