US 12,756,322 B2 · Fabrication trade-off based optimal synthesis of winding configurations for planar transformer in capacitor-inductor-inductor-capacitor (CLLC) direct current (DC)-DC converter

Abstract

Adhering to the objective of modelling and selecting the most optimal winding configuration for a high frequency planar transformer (HFPT) for auxiliary charging systems for more electric aircrafts (MEA) this disclosure elucidates numerous fabrication and design-based constraints and correlations to enable parametric modelling of various magnetic components. This disclosure characterizes possible winding configurations for HFPT employed in a bidirectional CUE DC/DC converter. A detailed analytical study is presented for each component and verified using several instances of 3D Finite Element Analysis (FEA) based model to synthesize the effective field and current density distribution in the windings. Several design-based trade-offs are graphically explained with various criteria pertaining to optimal winding selection to study the interdependence of the resultant parameters on hardware specifications, such as the PCB thickness and its fabrication layout, air gaps and conductor thickness.

Claims8

Dependent claims

A bidirectional resonant asymmetric capacitor-inductor-inductor-capacitor (CLLC) converter for charging applications, comprising:

a primary full or half-bridge comprising a primary port;
a secondary full or half-bridge comprising a second port;
and
a high frequency planar transformer (HFPT) that electrically couples the primary full or half-bridge and the secondary full or half-bridge, wherein asymmetry in values of inductance-capacitance (L-C) tank parameters produce voltage conversions from 400V-600V at the primary port to 24V-28V at the secondary port while maintaining efficient bidirectional power flow operation ranging from 96% to 98.5%.

1 more element

Dependencies are inferred from the claim text.

Facts

Application

18/323,980Filed 25 May 2023 · us provisional application

Priority

25 May 2022

Published

US 2023/0387816 A130 Nov 2023

Granted

6 Oct 2026

Term ends

Not estimatedThe source records don’t support an estimate.

Classification9 codes

H02M 3/33584
Having at least one active switching element at the secondary side of an isolation transformer: bidirectional converters
G06F 30/17
Geometric CAD: mechanical parametric or variational design
G06F 30/20
Computer-aided design [CAD]: design optimisation, verification or simulation
G06F 30/23
Design optimisation, verification or simulation: using finite element methods [FEM] or finite difference methods [FDM]

Fabrication trade-off based optimal synthesis of winding configurations for planar transformer in capacitor-inductor-inductor-capacitor (CLLC) direct current (DC)-DC converter

Life of this patent

Fabrication trade-off based optimal synthesis of winding configurations for planar transformer in capacitor-inductor-inductor-capacitor (CLLC) direct current (DC)-DC converter

Life of this patent

Abstract

Claims8