Three-Leg Magnetic Core Layout for Low-Ripple Power Conversion
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Solution Overview
Problem
Conventional power conversion modules with single-stage conversion structures face challenges such as large size, high power loss, high AC current ripple, and low magnetic saturation capability, making them unsuitable for long-sized and high-density electronic devices.
Innovation Solution
A power conversion module with a magnetic device featuring a magnetic core assembly and windings arranged in a specific configuration, where the magnetic resistance of certain legs is optimized, and windings are partially overlapped to reduce AC current ripple and enhance magnetic saturation resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional single-stage conversion structure is used, then power conversion efficiency is improved, but the module size becomes large
Solution Approach 1:
The magnetic core assembly is divided into multiple magnetic legs (first, second, third magnetic legs) with different magnetic resistances. The windings are segmented and disposed between different magnetic legs, creating modular functional units that can be independently optimized for performance while maintaining compact overall dimensions.
Solution Approach 2:
Different magnetic legs are designed with different magnetic resistance characteristics. The first and third magnetic legs have greater magnetic resistance than the second magnetic leg, creating localized magnetic field distributions that optimize both power conversion efficiency and reduce the overall module size.
2Ease of manufacture
If conventional magnetic device structure is used, then manufacturing is simplified, but power loss increases
Solution Approach 1:
The magnetic core is segmented into multiple legs with different magnetic resistance properties. This segmentation allows for optimized magnetic flux distribution that reduces power loss while maintaining a structure that can be manufactured using conventional techniques.
Solution Approach 2:
Different magnetic legs have different magnetic resistance characteristics tailored to their specific functional requirements. This local optimization of magnetic properties reduces overall power loss in the magnetic device while keeping the manufacturing process relatively simple.
3Device complexity
If conventional magnetic device structure is used, then device complexity is reduced, but AC current ripple increases
Solution Approach 1:
The magnetic core assembly is divided into multiple magnetic legs with different magnetic resistances. The windings are disposed between different magnetic legs, creating multiple magnetic flux paths that work together to reduce AC current ripple while maintaining manageable structural complexity.
Solution Approach 2:
Different magnetic legs have different magnetic resistance characteristics that are optimized to reduce AC current ripple. The first and third magnetic legs have greater magnetic resistance than the second magnetic leg, creating a magnetic flux distribution pattern that suppresses ripple currents.
4Ease of manufacture
If conventional magnetic device structure is used, then manufacturing is simplified, but magnetic saturation capability decreases
Solution Approach 1:
The magnetic core is divided into multiple legs with different magnetic resistance properties. This segmentation creates multiple magnetic flux paths with different saturation characteristics, allowing the device to handle higher overall magnetic loads before saturation occurs while maintaining conventional manufacturing approaches.
Solution Approach 2:
Different magnetic legs have different magnetic resistance characteristics that optimize the magnetic flux distribution. This local optimization increases the overall magnetic saturation capability of the device while keeping the manufacturing process relatively simple.
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 results in a compact, high-power-density module with reduced AC current ripple and improved magnetic saturation capability, suitable for long-sized and high-density applications like display cards or ASIC cards.
Implementation Method 1
A magnetic resistance of each of the first magnetic leg and the third magnetic leg is greater than a magnetic resistance of the second magnetic leg
Implementation Method 2
The first secondary winding is disposed between the first magnetic leg and the second magnetic leg, and the second secondary winding is disposed between the second magnetic leg and the third magnetic leg
Implementation Method 3
the capability of withstanding magnetic saturation is low
Data Source
AI summary
A magnetic device includes a magnetic core assembly, a first secondary winding, a second secondary winding and a primary winding. The magnetic core assembly includes a first magnetic leg, a second magnetic leg and a third magnetic leg. The first to third magnetic legs are arranged in sequence. The second magnetic leg is disposed between the first magnetic leg and the third magnetic leg. The first secondary winding is disposed between the first magnetic leg and the second magnetic leg, and the second secondary winding is disposed between the second magnetic leg and the third magnetic leg. A first terminal of the primary winding is disposed between the first magnetic leg and the second magnetic leg, and a second terminal of the primary winding is disposed between the second magnetic leg and the third magnetic leg.