Stacked Magnetic Core Layout for Flux-Canceling DC-DC Converters
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Solution Overview
Problem
The integration of multi-phase transformers and inductors for high-power applications is challenging due to flux crowding, eddy current losses, dimensional resonances, and physical size limitations, particularly in the context of data center power supply units exceeding 5 kW, which necessitates a more efficient use of the Z-axis optimization and reduced footprint.
Innovation Solution
A modular stacked magnetic component comprising vertically stacked magnetic cores with a shared magnetic cover and windings that form integrated transformers and inductors, where the current directions in adjacent windings are opposite for odd phases and the same for single phases, optimizing flux distribution and reducing volume and loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multi-phase transformers and inductors are integrated in conventional configurations, then power density increases, but flux crowding and eddy current losses occur
Solution Approach 1:
The patent transitions from planar integration to three-dimensional vertical stacking of magnetic cores. Multiple magnetic cores are stacked along the Z-axis with windings wrapped around them, creating a modular stacked configuration. This vertical arrangement distributes magnetic flux in the Z-direction, preventing flux crowding and reducing eddy current losses while maintaining high power density.
Solution Approach 2:
The integrated magnetic component is divided into multiple discrete magnetic cores stacked vertically, with each core having its own windings. This segmentation allows independent optimization of each core's flux path and reduces the harmful interactions between adjacent phases that cause eddy current losses in conventional integrated designs.
2Power
If multi-phase transformers and inductors are integrated in conventional configurations, then power density increases, but physical size limitations are reached
Solution Approach 1:
The patent utilizes the Z-axis vertical dimension for stacking magnetic cores, transforming the integration from a two-dimensional planar layout to a three-dimensional structure. This approach significantly increases power density without proportionally increasing the footprint area, effectively overcoming physical size limitations while maintaining compact form factor.
3Area of stationary object
If magnetic cores are stacked vertically to reduce footprint, then Z-axis utilization improves, but flux distribution deteriorates
Solution Approach 1:
The patent applies different winding configurations to different magnetic cores in the stack. Adjacent magnetic cores have windings with opposite current directions, creating localized flux patterns that cancel each other out. This local quality variation optimizes flux distribution throughout the stacked structure, preventing flux crowding while maintaining compact footprint.
Solution Approach 2:
The patent converts the potentially harmful magnetic flux from adjacent phases into a beneficial cancellation effect. By arranging windings on adjacent magnetic cores with opposite current directions, the magnetic fluxes interact to cancel each other out, improving overall flux distribution and reducing eddy current losses while maintaining the compact stacked structure.
4Ease of manufacture
If odd-phase converters use adjacent windings with same current direction, then manufacturing is simplified, but magnetic flux cancellation is reduced
Solution Approach 1:
The patent inverts the conventional approach by using opposite current directions in adjacent windings instead of the same direction. This inversion enables magnetic flux cancellation between adjacent phases, improving magnetic flux efficiency and reducing energy losses while maintaining a regular alternating pattern that is still manufacturable.
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 solution achieves better flux distribution, reduced volume, and lower losses by canceling out magnetic fluxes in adjacent cores, thereby optimizing the Z-axis utilization and minimizing the overall component size.
Implementation Method 1
The N windings are connected to the N phases of the DC-DC converter respectively, and each of the N windings is wound on the plurality of winding columns of a corresponding magnetic core to form an integrated transformer and inductor
Implementation Method 2
Any two adjacent windings, among the N windings, have opposite current directions. The solution achieves better flux distribution, reduced volume, and lower losses by canceling out magnetic fluxes in adjacent cores
Data Source
AI summary
A modular stacked magnetic component is provided. The modular stacked magnetic component is for a DC-DC converter with N phases, and N is an odd number greater than 1. In the N phases, an nth phase is 360/N degrees leading an (n+1)th phase, n is a positive integer less than N, and an Nth phase is 360/N degrees leading a first phase. The modular stacked magnetic component includes N magnetic cores, a magnetic cover, and N windings. The N magnetic cores are stacked vertically in sequence. The magnetic cover is stacked on the top of the N magnetic cores. The N windings are connected to the N phases of the DC-DC converter respectively, and each winding is wound on winding columns of a corresponding magnetic core to form an integrated transformer and inductor. Any two adjacent windings have opposite current directions.