Transformer Primary Winding Segmentation for Heat Dissipation
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Solution Overview
Problem
The existing two-transformer circuit configuration for reducing temperature increase in transformers used in large output converters leads to increased wiring loss and complexity due to the need for additional wires, which lowers efficiency and increases component costs.
Innovation Solution
A transformer design where the primary winding is split into two series-connected windings with opposite magnetic flux directions, and the secondary winding is configured to reduce wire interference and eliminate the need for additional connecting wires, thereby dispersing heat and reducing the number of turns required.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a two-transformer circuit configuration is used to reduce temperature increase, then heat radiation is improved, but wiring loss increases and device complexity increases
Solution Approach 1:
The primary winding is segmented into two separate windings (first primary winding and second primary winding) wound around different cores (first core and second core), allowing heat to be dispersed across multiple components rather than concentrated in a single transformer, thereby reducing temperature increase while maintaining electrical connection through series configuration
2Temperature
If a two-transformer circuit configuration is used to reduce temperature increase, then heat radiation is improved, but device complexity increases
Solution Approach 1:
The first primary winding and second primary winding are electrically connected in series, merging their electrical functions into a single continuous circuit path. This series connection simplifies the wiring structure by eliminating the need for additional connecting wires between separate transformers, while still achieving heat dispersion through the distributed winding configuration
3Temperature
If the primary winding is split into two series-connected windings with opposite magnetic flux directions, then temperature increase is suppressed, but the winding structure becomes more complex
Solution Approach 1:
The magnetic flux directions in the first primary winding and second primary winding are configured to be opposite to each other, creating localized magnetic field characteristics that reduce core saturation and improve heat distribution. This local optimization of magnetic flux direction allows the use of standard winding techniques while achieving superior thermal performance
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 effectively suppresses temperature increase, reduces wiring loss, and enables a low-profile, highly efficient power converter with improved heat radiation properties.
Implementation Method 1
a first primary winding 103a wound around a first core 101a and a second primary winding 104a wound around a second core 102a and electrically connected in series to the first primary winding 103a, wherein the first primary winding 103a is disposed such that a direction of magnetic flux on an inner peripheral side of the first primary winding 103a induced by the first primary winding 103a is opposite to a direction of magnetic flux on an inner peripheral side of the second primary winding 104a induced by the second primary winding 104a
Implementation Method 2
Since the primary winding and the secondary winding have a resistance component, a copper loss is caused by conduction, and heat is generated
Implementation Method 3
Therefore, resistance components of the primary winding and the secondary winding increase by a skin effect in comparison with a DC resistance
Implementation Method 4
when the DC-DC converter operates, an AC magnetic flux is applied to a core of the transformer. Consequently, an iron loss is caused to the core, and heat is generated
Data Source
AI summary
To suppress a temperature increase of a transformer. A transformer includes a core, a primary winding, and a secondary winding. The core includes a primary core and a secondary core disposed on a side of the primary core. The primary winding includes a first primary winding wound around the primary core and the second primary winding wound around the secondary core and electrically connected in series to the first primary winding. The first primary winding is disposed such that a direction of a magnetic flux on an inner peripheral side of the first primary winding induced by the first primary winding is opposite to a direction of the magnetic flux on the inner peripheral side of the second primary winding induced by the second primary winding. The secondary winding is wound such that a winding axial line of the first primary winding and a winding axial line of the second primary winding are formed on an inner peripheral side of the secondary winding.