Integrated Transformer-Inductor Layout for Flux Decoupling
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Solution Overview
Problem
Existing transformer designs with integrated inductors face issues of large size, low power density, high loss, and low flexibility due to high transformer coupling, leading to increased complexity and production costs.
Innovation Solution
A transformer design with an integrated inductor that incorporates a magnetic core with a magnetic yoke and columns, where the inductor winding is partially accommodated within the magnetic core, decoupling its magnetic flux from the transformer winding, allowing for a compact structure and improved power density without additional magnetic cores.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the inductor Lr is integrated using leakage inductance Lk of transformer, then cost is reduced, but space between primary and secondary sides must be left, causing transformer winding to become longer and power density to decrease
Solution Approach 1:
The patent extracts the inductor function from the transformer structure by using an independent magnetic core for the inductor, separate from the transformer magnetic core. This allows the inductor winding to be wound independently around its own magnetic core, eliminating the need to leave space between primary and secondary windings for leakage inductance, thereby maintaining high power density while achieving inductor integration
Solution Approach 2:
The patent merges the transformer and inductor into a single integrated component by providing a common housing that accommodates both the transformer magnetic core with transformer winding and the inductor magnetic core with inductor winding. This integration achieves cost reduction through unified packaging and assembly while maintaining independent magnetic paths for both functions
2Reliability
If magnetic core integration method is used, then maximum value of magnetic flux density may be reduced, but additional part of magnetic core is provided for inductor, resulting in low power density and increased complexity
Solution Approach 1:
The patent segments the magnetic paths by providing separate magnetic cores for the transformer and inductor functions. The transformer magnetic core has its own magnetic path for transformer magnetic flux, and the inductor magnetic core has its own magnetic path for inductor magnetic flux. This segmentation allows each magnetic path to operate independently at optimal flux density levels without sharing magnetic core space, thereby maintaining high power density
3Reliability
If inductor winding is accommodated in magnetic yoke or magnetic column, then decoupling of magnetic flux is achieved, but structure complexity increases
Solution Approach 1:
The patent implements nesting by placing the inductor magnetic core inside the housing that also contains the transformer magnetic core. The inductor winding is wound around the inductor magnetic core which is positioned within the same housing as the transformer components. This nested arrangement achieves magnetic flux decoupling while maintaining a compact structure that does not significantly increase overall complexity
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 simplifies assembly, enhances manufacturing efficiency, reduces space occupation, and increases power density by allowing the transformer winding to be wound closely, while maintaining independent operation of the transformer and inductor windings.
Implementation Method 1
the inductor winding is at least partially accommodated in at least one magnetic yoke or at least one magnetic column of the magnetic core, so that the inductor winding penetrates through the transformer winding space formed by the transformer winding on a single magnetic column at most once, thereby decoupling the magnetic flux produced by the inductor winding from the magnetic flux produced by the transformer winding
Data Source
AI summary
The disclosure provides a transformer with an integrated inductor, including a magnetic core, a transformer winding and an inductor winding. The magnetic core comprises a magnetic yoke and magnetic columns connected to the magnetic yoke. The transformer winding is wound around at least one of the magnetic columns, and at least one transformer winding space is formed in the transformer winding. The inductor winding is at least partially accommodated in at least one magnetic yoke or at least one magnetic column of the magnetic core, so that the inductor winding penetrates through the transformer winding space formed by the transformer winding on a single magnetic column at most once, thereby decoupling the magnetic flux produced by the inductor winding from the magnetic flux produced by the transformer winding.