Stacked Magnetic Core Integration for Compact Voltage Converters
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Solution Overview
Problem
Magnetic components in circuits, such as transformers and inductors, occupy a significant portion of the overall size, making it difficult to reduce the size of circuit assemblies like voltage converters.
Innovation Solution
Integrating magnetic cores for transformers and inductors into a single, stacked structure with specific column arrangements, allowing for reduced overall size and improved heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If magnetic components (transformer and inductors) are designed, manufactured and packed separately, then each component can be optimized independently, but the overall size of the circuit assembly becomes large
Solution Approach 1:
The patent combines multiple magnetic components (transformer and inductors) into a single integrated magnetic apparatus with a unified core structure. The first, second, and third magnetic cores are stacked and coupled to form an integrated assembly that houses both the transformer winding and inductor windings, eliminating the need for separate component packaging and reducing overall assembly size.
Solution Approach 2:
The integrated magnetic apparatus serves multiple functions within a single structure. The stacked magnetic cores provide magnetic paths for both transformer operation and inductor operation, allowing the same magnetic assembly to perform energy transfer and energy storage functions simultaneously, thereby reducing the number of separate components needed.
2Reliability
If transformer and inductor are assembled together in a specific circuit, then circuit functionality is achieved, but the size reduction is limited
Solution Approach 1:
The patent implements a nested structure where the transformer winding and inductor windings are both wound around the same stacked magnetic core assembly. The first winding is associated with the first magnetic core, while the second and third windings are associated with the second and third magnetic cores, creating a compact nested arrangement that maximizes space utilization.
Solution Approach 2:
The patent transitions from planar or side-by-side component arrangement to a three-dimensional stacked configuration. The magnetic cores are stacked vertically (first core, second core, third core in sequence), and windings are arranged in different spatial dimensions around these cores, effectively utilizing vertical space to reduce the horizontal footprint of the assembly.
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 integrated magnetic apparatus reduces the overall size of circuit assemblies by approximately 50% while maintaining performance, with improved heat dissipation and higher power density.
Implementation Method 1
a magnetic path of the transformer is configured to go through the first column, the second planar body, the fourth column, and the first planar body
Data Source
AI summary
The present disclosure relates to a magnetic apparatus, and a voltage converter including the same. The magnetic apparatus comprises: a first magnetic core (1), including a first planar body (11); a second magnetic core (2), including a second planar body (21); and a third magnetic core (3), including a third planar body (31). The first, second, and third magnetic core (3) are sequentially stacked. The magnetic apparatus further comprises: a first column (101) for a transformer, located between and basically perpendicular to the first planar body (11) and the second planar body (21); at least two second columns (102) for at least two inductors, located between and basically perpendicular to the second planar body (21) and the third planar body (31).