Transformer Barrier Rib for Inductance and Noise Control
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Solution Overview
Problem
Existing power conversion apparatuses for photovoltaic modules face challenges in miniaturization, ease of processing, and reduction of electromagnetic noise and copper loss due to the difficulty in adjusting leakage inductance and the circular shape of internal walls in integrated type transformers.
Innovation Solution
The design includes a transformer with a first and second core, each with a protrusion member and external wall, and a barrier rib separating the windings, allowing for equal winding lengths and reducing processing complexity and electromagnetic noise, while incorporating a magnetic barrier rib to adjust inductance and minimize copper loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a circular internal wall and second circular internal wall are disposed within an external wall of a first core in an integrated type transformer, then leakage inductance can be formed, but it is not easy to process the internal walls and adjust leakage inductance to meet design specifications
Solution Approach 1:
The transformer structure is divided into separate modular components: a first core with first winding, a second core with second winding, and a barrier rib. This segmentation replaces the complex circular internal walls with simpler rectangular cores and a separate barrier rib component, making each part easier to manufacture while maintaining the leakage inductance function through the barrier rib's positioning between the windings
Solution Approach 2:
A barrier rib is introduced as an intermediary component between the first winding and second winding. This barrier rib serves as the leakage inductance element and separator, replacing the need for complex circular internal walls within the core. The barrier rib can be independently manufactured and positioned, significantly simplifying the overall manufacturing process while achieving the required leakage inductance
2Reliability
If a transformer and leakage inductor are each installed on a circuit board, then they can function independently, but a large volume is occupied
Solution Approach 1:
The transformer and leakage inductor are merged into a single integrated structure. The first core with first winding and second core with second winding form the transformer, while the barrier rib between them provides the leakage inductance function. This integration eliminates the need for separate components, reducing overall volume while maintaining independent functional characteristics through the barrier rib's design
3Ease of manufacture
If the first winding and second winding have different lengths, then they can be wound independently, but copper loss increases
Solution Approach 1:
The first core and second core are designed with the same height, creating equipotential conditions for winding length. This design enables both windings to have equal lengths, minimizing copper loss while still allowing independent winding processes. The equal height specification ensures that windings of the same length can be achieved without compromising manufacturing independence
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 configuration enables easier processing, reduces the size of the transformer, minimizes electromagnetic noise, and reduces copper loss by allowing for adjustable inductance and equal winding lengths, thereby enhancing the efficiency of the power conversion apparatus.
Implementation Method 1
a barrier rib configured to separate the first winding and the second winding from each other. The barrier rib may include a magnetic material.
Implementation Method 2
a first core including a base, a first protrusion member to protrude from the base, and a first external wall spaced apart from the first protrusion member and to surround the first protrusion member, a first winding wound in the first core, a second core including a second base, a second protrusion member to protrude from the second base, and a second external wall spaced apart from the second protrusion member and to surround the second protrusion member, a second winding wound in the second core
Data Source
AI summary
Disclosed are a transformer, and a power conversion apparatus or a photovoltaic module including the same. The transformer includes a first core including a base, a first protrusion member to protrude from the base, and a first external wall spaced apart from the first protrusion member and to surround the first protrusion member, a first winding wound in the first core, a second core including a second base, a second protrusion member to protrude from the second base, and a second external wall spaced apart from the second protrusion member and to surround the second protrusion member, a second winding wound in the second core, and a barrier rib configured to separate the first winding and the second winding from each other. Thus, ease of processing is achieved and radiation of electromagnetic noise is reduced.