Split-Core Transformer Gaps for Adjustable Leakage Inductance
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Solution Overview
Problem
Existing transformers face challenges in miniaturization due to the need for additional components to adjust leakage inductance, and in split-tank transformers, the leakage inductance value is fixed during manufacturing, limiting flexibility and commonality.
Innovation Solution
A transformer design featuring a core group with a middle portion and external portions, where the first and second gaps between these components allow for adjustable primary and leakage inductance values, enabling size reduction and flexibility in inductance adjustment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a resonant inductance is added to the primary transformer to adjust leakage inductance, then the leakage inductance can be adjusted, but the space required increases due to additional components
Solution Approach 1:
The patent combines the primary transformer and resonant inductance into a single integrated transformer structure. The primary coil and resonant coil are wound on the same magnetic core, eliminating the need for separate components and reducing overall space while maintaining leakage inductance adjustability through tap connections.
Solution Approach 2:
The transformer structure serves multiple functions simultaneously: the primary coil provides primary inductance, the resonant coil provides leakage inductance, and the tap connections enable adjustable coupling between them. This multi-functionality allows one device to replace what would traditionally require multiple separate components.
2Device complexity
If the coils are separated by air in a split-tank transformer to control leakage inductance, then no additional components are required, but the leakage inductance value cannot be adjusted after manufacturing
Solution Approach 1:
The patent introduces adjustable tap connections that allow the coupling between primary and resonant coils to be dynamically changed after manufacturing. This enables the leakage inductance value to be adjusted post-manufacturing, transforming a static design into a dynamic one that adapts to different requirements.
Solution Approach 2:
The patent changes the electrical parameters of the transformer by providing multiple tap connections on both primary and resonant coils. By selecting different tap combinations, the effective number of turns and coupling ratio can be changed, thereby adjusting the leakage inductance value without physical modifications to the coil structure.
3Ease of manufacture
If the number of turns of coils is defined during manufacturing to control leakage inductance, then the structure is simple, but the leakage inductance value is fixed and commonality is reduced
Solution Approach 1:
The patent segments the coils into multiple sections with tap connections at various points along their length. This segmentation allows selective connection of different portions of the coils, enabling multiple inductance values to be achieved from a single manufactured structure without complicating the manufacturing process.
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 design achieves a transformer with high commonality and small space by allowing adjustable inductance values through gap adjustments, enhancing miniaturization and flexibility.
Implementation Method 1
the first coil and a second coil... the first coil surrounds the lower section of the middle portion and the second coil surrounds the upper section of the middle portion, so the primary inductance and the leakage inductance may be generated
Data Source
AI summary
The present disclosure is related to a transformer. The transformer includes a core group, a first coil and a second coil. The core group includes two external portions and a middle portion. The middle portion is located between the two external portions. The middle portion has an upper section, a middle section and a lower section. Each of the upper section and the lower section has a first gap between one of the two external portions. The middle section has a second gap between one of the two external portions. The first gap is different from the second gap. The first coil surrounds the lower section of the middle portion. The second coil surrounds the upper section of the middle portion.