Segmented Transformer Winding for On-Board Charger Heat Dissipation
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Solution Overview
Problem
High-frequency on-board charger (OBC) modules face challenges in reducing the size and weight of magnetic components while maintaining heat dissipation and conversion efficiency, as increased switching frequency leads to increased heat dissipation difficulties with integrated magnetic components.
Innovation Solution
A transformer design with a magnetic core, winding region, primary coil, and secondary coil, where the coils are alternately wound in multiple layers along a winding column, reducing the number of winding layers and enhancing heat dissipation through increased surface area for thermal exchange, and the transformer is integrated into a DC-DC converter for efficient power conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If integrated magnetic components are adopted to reduce size, then the volume of the transformer is reduced, but the heat dissipation becomes harder
Solution Approach 1:
The transformer winding is divided into multiple independent winding units (first winding unit, second winding unit, third winding unit) arranged along the axial direction. Each winding unit contains primary and secondary coils that can be independently designed and arranged, allowing heat generated in each unit to dissipate separately rather than accumulating in a single integrated structure.
Solution Approach 2:
The patent transitions from planar winding arrangements to three-dimensional stacked winding units arranged along the axial direction of the magnetic core. This vertical stacking creates additional thermal pathways and increases the surface area for heat dissipation while maintaining a compact overall volume, effectively utilizing the third dimension to resolve the heat dissipation issue.
2Volume of moving object
If switching frequency is increased to reduce component size, then the volume of magnetic components is reduced, but heat dissipation difficulties increase
Solution Approach 1:
Different winding units are designed with different local characteristics - the first, second, and third winding units can have different numbers of turns, different wire gauges, or different winding densities optimized for their specific thermal and electrical requirements. This allows high-frequency operation in regions with better heat dissipation while maintaining compact overall size.
Solution Approach 2:
The magnetic core acts as an intermediary that magnetically couples the primary and secondary coils across different winding units while providing thermal pathways. The segmented winding units serve as intermediaries that distribute heat generation across multiple locations, preventing heat accumulation and enabling high-frequency operation in a compact form factor.
3Power
If multiple winding layers are used in each winding unit, then the transformation ratio can be achieved, but the number of winding layers increases complexity and volume
Solution Approach 1:
The total transformation ratio is achieved by segmenting the winding structure into multiple winding units along the axial direction, with each unit contributing a portion of the total turns. This distributes the complexity across multiple simpler units rather than requiring many layers in a single unit, reducing manufacturing complexity while maintaining the required transformation ratio.
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 reduces the volume and weight of the transformer, improves heat dissipation, and maintains high conversion efficiency for OBC modules, suitable for high-frequency operations between 400 kHz and 1 MHz.
Implementation Method 1
The transformer includes a primary winding and a second winding magnetically coupled to each other
Data Source
AI summary
A transformer and a DC-DC converter for on-board charger using the same are provided. The transformer includes a magnetic core, a winding region, a primary coil and a secondary coil. The magnetic core includes two cover plates and a winding column disposed between the two cover plates. The winding region is disposed on the winding column and includes a plurality of winding units. The primary coil is wound in a part of the winding units to form a primary winding of the transformer. The secondary coil is wound in the other part of the winding units to form a secondary winding of the transformer. The primary and secondary coils are at least partially wound alternately in part of the plurality of winding units, and a number of winding layers along an axial direction of the winding column in each winding unit is less than or equal to two.