Transformer Shared-Winding Rectifier Layout for High Power Density
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Solution Overview
Problem
Current power supply modules face challenges in achieving high power density and dynamic performance due to complex connections and high rectifier component requirements in multi-phase parallel configurations, leading to increased costs and connection losses.
Innovation Solution
A power supply module design featuring a transformer with a magnetic core and winding, along with a full bridge rectifier circuit where the rectifier components are connected in series to a shared winding portion, reducing the number of components and simplifying the structure, and improving efficiency by reusing the winding and rectifier components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple phases are connected in parallel for half-bridge full-wave rectification or full-bridge rectification, then the current output capability is improved, but the number of rectifier components increases and the structure becomes more complex
Solution Approach 1:
The patent merges the primary and secondary windings into a single integrated winding structure with alternating winding sections. This combined winding serves both the primary circuit and secondary circuit simultaneously, eliminating the need for separate windings and reducing the overall number of components in the transformer assembly.
Solution Approach 2:
The integrated winding structure performs multiple functions: it acts as both the primary winding for the primary circuit and the secondary winding for the secondary circuit. The alternating winding sections enable the same physical structure to support both rectification circuits, reducing component count while maintaining multi-phase parallel operation capability.
2Power
If multiple phases are connected in parallel for half-bridge full-wave rectification or full-bridge rectification, then the current output capability is improved, but the connection between windings and rectifier components becomes complicated, increasing connection loss
Solution Approach 1:
The patent combines the primary and secondary windings into a single integrated structure where the windings are physically adjacent and electrically connected through the alternating sections. This merging reduces the number of connection points and minimizes connection loss by eliminating intermediate connection interfaces between separate windings and rectifier components.
3Power
If one level of power of the power supply is improved, then the power density is increased, but more rectifier components shall be added, which does not facilitate subdividing power level and reducing cost
Solution Approach 1:
The patent segments the winding into alternating primary and secondary sections that can be independently configured. This segmentation allows the power supply to achieve higher power density by optimizing the winding arrangement without proportionally increasing the number of discrete rectifier components, as the integrated structure shares common elements between phases.
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 enhances power density, reduces component costs, and minimizes connection losses by reusing shared windings and rectifier components, facilitating easier power level subdivision and improved manufacturing efficiency.
Implementation Method 1
The primary winding converts electrical energy to the secondary winding through electromagnetic induction according to Faraday's Law of Electromagnetic Induction
Data Source
AI summary
The disclosure provides a power supply module, including a transformer including magnetic core and winding, and a rectifier circuit electrically connected to the winding, wherein the magnetic core further comprises: a first and a second cover plate opposite to each other; a first magnetic column; and a second magnetic column having a magnetic flux in opposite direction to that of the first magnetic column, the first and second magnetic column connected between the first and the second cover plate; the winding further includes: a first winding wound onto the first magnetic column; and a second winding wound onto the second magnetic column, wherein the first and second winding have a shared winding portion at least partially located between the first and second magnetic column; the rectifier circuit includes a plurality of rectifier components including first to fourth rectifier component electrically connected to form a full bridge rectifier circuit.