U-Shaped Core Magnetic Device Winding Distribution
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Solution Overview
Problem
Conventional magnetic devices in power converters have inefficiencies due to single-layer windings that do not utilize the horizontal walls of 'E' or 'I' core pieces, leading to high power losses and limited distribution of winding turns.
Innovation Solution
A magnetic device formed with U-shaped core pieces positioned on a rectilinear core piece, allowing for conductive windings to be formed over the full span of these pieces, thereby increasing the physical space for winding turns and reducing proximity effects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If single-layer windings are used to reduce proximity effect, then power conversion efficiency is improved, but the distribution of winding turns is limited and horizontal walls of core pieces are not utilized
Solution Approach 1:
The patent transitions from winding turns confined to vertical walls to windings that utilize both vertical and horizontal walls of the E-core pieces. This dimensional expansion allows winding turns to be distributed across the full span of the core pieces, increasing the effective area for windings while maintaining single-layer configuration to minimize proximity effects.
Solution Approach 2:
The patent divides the winding structure into multiple segments distributed across different walls of the E-core pieces. Instead of concentrating all windings on vertical walls, the winding turns are segmented and placed on both vertical and horizontal walls, achieving wider distribution and better utilization of core piece surfaces.
2Ease of manufacture
If windings are confined to vertical walls of E-core pieces, then manufacturing is simplified, but horizontal walls are not utilized leading to high power losses
Solution Approach 1:
The patent makes all surfaces of the E-core pieces (both vertical and horizontal walls) functional for winding placement. Previously, horizontal walls served no winding function; now they are utilized to carry winding turns, making the entire core piece surface area productive and reducing energy losses from unused magnetic material.
3Ease of manufacture
If conventional rectilinear core pieces are used, then manufacturing is practical, but winding turns cannot be widely distributed leading to proximity effects
Solution Approach 1:
The patent utilizes the horizontal dimension of the E-core pieces for winding placement, in addition to the vertical dimension. This allows winding turns to be spread out across a larger surface area encompassing both vertical and horizontal walls, reducing current density and proximity effects while maintaining manufacturable rectilinear core geometry.
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 enhances power conversion efficiency by allowing a wider distribution of winding turns, reducing power losses associated with high-frequency currents and improving the overall performance of power converters.
Implementation Method 1
A high-frequency alternating current ('ac') voltage is applied to a winding of the magnetic device that is typically converted to another voltage level by an inductive action of the magnetic device
Implementation Method 2
a rectilinear core piece formed of a magnetic material, and first and second U-shaped core pieces positioned on the rectilinear core piece
Data Source
AI summary
A magnetic device formed with U-shaped core pieces employable in a power converter, and a method of forming the same. In one embodiment, the magnetic device includes a rectilinear core piece formed of a magnetic material, and first and second U-shaped core pieces positioned on the rectilinear core piece. The magnetic device also includes first and second conductive windings formed about the first and second U-shaped core pieces, respectively.