Transformer Core Protrusions for Leakage Inductance Control
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Solution Overview
Problem
Existing transformer designs for photovoltaic modules face challenges in controlling leakage inductance due to fixed core spaces, making it difficult to achieve compact and customizable power converting apparatuses.
Innovation Solution
A core design with a base, outer wall, and protruding members allows for easy machining and control of leakage inductance, integrating a transformer and leakage inductor to reduce size and enhance design flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a circular inner wall and second circular inner wall are disposed in the core to produce leakage inductance, then leakage inductance is generated, but easy machining is not allowed and leakage inductance cannot be easily controlled according to design specification
Solution Approach 1:
The patent applies curvature by using a circular protruding member instead of straight edges. The circular shape of the first protruding member creates a controlled air gap with the second protruding member, generating the necessary leakage inductance while maintaining ease of machining through standard circular profiling operations.
Solution Approach 2:
The patent implements local quality by creating a specific air gap structure between the first and second protruding members. The air gap is localized to specific regions (with different gap lengths in different areas) to control the leakage inductance distribution, allowing precise control of magnetic flux paths while maintaining overall structural simplicity.
2Manufacturing precision
If the core space is fixed at the center, then structural stability is maintained, but it is difficult to control leakage inductance
Solution Approach 1:
The patent applies segmentation by dividing the core into distinct functional regions: a fixed central core space for structural stability, and peripheral protruding members for leakage inductance control. The first and second protruding members are positioned at specific locations (e.g., bottom and side) to create controlled air gaps without disrupting the central core's fixed structure.
3Volume of moving object
If transformer and leakage inductor are mounted separately on circuit board, then functional requirements are met, but they occupy considerable volume
Solution Approach 1:
The patent implements merging by integrating the leakage inductor function directly into the transformer core structure. The first and second protruding members on the same core create the air gap necessary for leakage inductance, eliminating the need for a separate leakage inductor component and reducing overall volume while maintaining functional requirements.
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 enables precise control of leakage inductance and reduces the overall size of the transformer, facilitating the creation of compact and efficient power converting apparatuses for photovoltaic modules.
Implementation Method 1
a first bobbin surrounding the first protruding member in the core; and a second bobbin surrounding the first protruding member and the second protruding member in the core
Data Source
AI summary
Disclosed are a core, a transformer, a power converting apparatus, and a photovoltaic module including the same. The core includes: a base; outer wall formed on the base; a first protruding member protruding on the base and disposed within the outer wall; and a second protruding member protruding on the base, disposed within the outer wall, and separated from the first protruding member, wherein a length of an edge of the second protruding member opposing the first protruding member is less than an outer circumference of the first protruding member. Accordingly, the second protruding member may be machined so easily that a leakage inductance can be easily controlled according to design specification.