An inductor

Abstract

This application relates to the field of inductor technology and provides an inductor including: multiple sets of coils and a magnetic core; the magnetic core includes: an upper base plate and a lower base plate arranged parallel to each other, multiple winding posts located between the upper base plate and the lower base plate and wound with the multiple sets of coils, and at least one non-winding post disposed between the upper base plate and the lower base plate; the number of turns of the coils on at least two of the winding posts is different, and the direction of the current in the coils is opposite; each of the at least two winding posts with different numbers of turns has an air gap, and the size of the air gap on each winding post is different. The inductor in this embodiment can be configured with different ratios of magnetic loss and copper loss according to the different heat dissipation conditions of the environment in which the inductor is located, realizing differentiated design of the inductor.

Description

Technical Field

[0001] This application relates to the field of inductor technology, and particularly to an inductor. Background Technology

[0002] In the field of inductor technology, especially in high-power converters, the use of interleaved parallel technology can effectively reduce current ripple and achieve higher power density and efficiency. Therefore, the number of required magnetic components inevitably increases. If discrete inductors are still used, the size increases significantly, occupying a large amount of space. Therefore, using an integrated structure can effectively reduce the core size and improve efficiency. However, existing integrated inductors do not provide solutions to problems such as uneven heat dissipation of actual magnetic components and efficiency issues. Summary of the Invention

[0003] The main objective of this application is to propose an inductor that can be configured with different ratios of magnetic loss and copper loss depending on the heat dissipation conditions of the environment in which the inductor is located, thereby realizing the differentiated design of the inductor.

[0004] To achieve the above objectives, this application provides an inductor comprising: multiple sets of coils and a magnetic core; the magnetic core comprising: an upper base plate and a lower base plate arranged parallel to each other, multiple winding posts located between the upper base plate and the lower base plate and wound with the multiple sets of coils, and at least one non-winding post disposed between the upper base plate and the lower base plate; the number of turns of the coils on at least two of the winding posts is different, and the direction of the current in the coils is opposite; each of the at least two winding posts with different numbers of turns has an air gap, and the size of the air gap on each winding post is different.

[0005] The inductor proposed in this application includes: multiple sets of coils and a magnetic core; the magnetic core includes: an upper base plate and a lower base plate arranged parallel to each other, multiple winding posts located between the upper base plate and the lower base plate and wound with multiple sets of coils, and at least one non-winding post located between the upper base plate and the lower base plate. At least two winding posts have different numbers of turns and opposite directions of current within their coils. Each of the at least two winding posts with different numbers of turns has an air gap, and the size of the air gap on each winding post is different. By setting at least two winding coils with different numbers of turns and different air gap sizes, this solution allows for adjustment of the proportions of magnetic loss and copper loss compared to an inductor with the same number of turns and the same air gap. Therefore, in practical applications, inductors with different turns ratios can be set according to different heat dissipation conditions in the environment, achieving differentiated design. Attached Figure Description

[0006] One or more embodiments are illustrated by way of example with reference to the accompanying drawings, and these illustrative descriptions do not constitute a limitation on the embodiments.

[0007] Figure 1 This is a schematic diagram of the structure of an inductor according to an example of this application;

[0008] Figure 2 This is a schematic diagram of the structure of an inductor based on an existing example;

[0009] Figure 3 This is a core loss distribution diagram based on two inductors with different turns ratios according to this application;

[0010] Figure 4 This is a schematic diagram of the structure of an inductor according to another example of this application. Specific Implementation

[0011] To make the objectives, technical solutions, and advantages of the embodiments of this application clearer, the various embodiments of this application will be described in detail below with reference to the accompanying drawings. However, those skilled in the art will understand that many technical details have been provided in the various embodiments of this application to help readers better understand this application. However, the technical solutions claimed in this application can be implemented even without these technical details and various changes and modifications based on the following embodiments. The division of the various embodiments below is for the convenience of description and should not constitute any limitation on the specific implementation of this application. The various embodiments can be combined with and referenced by each other without contradiction.

[0012] In the field of inductor technology, especially in high-power converters, the interleaved parallel connection technology can effectively reduce current ripple and achieve higher power density and efficiency. Therefore, the number of required magnetic components inevitably increases. If discrete inductors are still used, the size increases significantly, occupying a large space. Therefore, using an integrated structure can effectively reduce the core size and improve efficiency. The following content in this embodiment mainly addresses issues such as uneven heat dissipation and efficiency of actual magnetic components, proposing differentiated designs based on copper losses and magnetic losses.

[0013] See Figure 1 In one embodiment, the inductor includes: multiple sets of coils 1 and a magnetic core 2; the magnetic core 2 includes: an upper base plate 21 and a lower base plate 22 arranged parallel to each other, multiple winding posts 23 located between the upper base plate 21 and the lower base plate 22 and wound with the multiple sets of coils 1, and at least one non-winding post 24 disposed between the upper base plate 21 and the lower base plate 22. The number of turns of the coils 1 on at least two winding posts 23 is different, and the direction of the current in the coils 1 is opposite. At least two winding posts 23 with different numbers of turns each have an air gap 10, and the size of the air gap 10 on each winding post 23 is different.

[0014] Optionally, the air gap 10 is located at a position on the winding post 23 away from the upper base plate 21 and the lower base plate 22, and each winding post 23 is connected to both the upper base plate 21 and the lower base plate 22. That is, the air gap 10 is located in the middle region of the winding post 23, and each winding post 23 is connected to both the upper base plate 21 and the lower base plate 22. The air gap 10 can be a single-segment air gap 10 or multiple-segment air gaps 10.

[0015] In this embodiment, the magnetic core 2 includes non-wound posts 24, wound posts 23, an upper base plate 21, and a lower base plate 22. The material of the magnetic core 2 includes ferrite, amorphous material, magnetic powder core, or silicon steel. In practical applications, the materials of the non-wound posts 24, wound posts 23, and the upper and lower base plates 21 and 22 may be the same or different. The upper and lower base plates 21 and 22 may be plate-shaped. The two ends of each of the multiple wound posts 23 are respectively connected to the upper and lower base plates 21 and 22, and the two ends of at least one non-wound post 24 are respectively connected to the upper and lower base plates 21 and 22.

[0016] Optionally, the non-winding post 24, the winding post 23, the upper base plate 21, and the lower base plate 22 are integrally formed.

[0017] Optionally, the upper base plate 21 and the lower base plate 22 may adopt a hexagonal or other polygonal structure, and the winding post 23 and the non-winding post 24 may be elliptical, circular, or polygonal.

[0018] The inventors discovered that increasing the number of turns on a single winding post 23 and increasing the air gap by 10 increases the overall copper loss and decreases the magnetic loss of the inductor. Conversely, decreasing the number of turns on a single winding post 23 and decreasing the air gap by 10 decreases the overall copper loss and increases the magnetic loss. In practical applications of inductors in communication power supplies or other switching power supplies, whether in environments with natural or air cooling, there are near-airflow and leeward surfaces, or surfaces near or far from heat sources. Therefore, differentiated optimal designs can be implemented based on the specific circumstances. For example, in the near-airflow surface where heat dissipation is better, the number of turns on the winding post 23 can be increased by 10, and the air gap increased by 10, to reduce magnetic loss; conversely, in the far-airflow surface where heat dissipation is poor, the number of turns on the winding post 23 can be decreased to reduce copper loss. This allows for differentiated designs considering heat dissipation and efficiency, striking a balance between magnetic and copper losses, and improving inductor utilization while addressing heat dissipation issues.

[0019] Based on the above theory, this embodiment proposes that at least two winding posts 23 in the inductor have different numbers of turns of coil 1 and that the directions of the current in coil 1 are opposite. At least two winding posts 23 with different numbers of turns each have an air gap 10, and the size of the air gap 10 on each winding post 23 is different.

[0020] In this configuration, at least two winding posts 23 have different numbers of turns for coil 1, and the directions of the current in coil 1 are opposite. This allows the magnetic flux on the non-wound post 24 to weaken each other. Based on this, the cross-sectional area of ​​the non-wound post 24 can be smaller than that of the winding post 23. Reducing the volume of the non-wound post 24 not only reduces the magnetic loss of the magnetic core 2 but also improves the integration density of the inductor and reduces its volume.

[0021] To meet the design requirements of power electronic products, the magnetic core 2 is typically polished to create an air gap 10 to adjust the inductance. The air gap 10 reduces the permeability, making the coil characteristics less dependent on the initial permeability of the core 2 material. The air gap 10 can prevent magnetic saturation under large AC signals or DC bias, allowing for better control of the inductance. However, reducing the permeability with the air gap 10 requires a larger number of turns in the coil 1, which also increases copper losses, so a trade-off is necessary. In this embodiment, since the number of turns of the coil 1 on at least two winding posts 23 is different, the sizes of the air gaps 10 on the two winding posts 23 are also different to ensure that the inductance values ​​formed by the coil 1 on the two winding posts 23 are similar. Each of the at least two winding posts 23 has one or more air gaps 10, and the sizes of the air gaps 10 on the two winding posts 23 with different numbers of turns of the coil 1 are also different. It is worth noting that, for the purpose of explaining the technical principle of this embodiment using the controlled variable method, the current flowing through each coil 1 in this embodiment is the same.

[0022] In this scheme, by setting at least two winding coils 1 with different numbers of turns and different air gap 10 sizes, the proportion of magnetic loss and copper loss can be adjusted compared to the original inductor with the same number of turns and the same air gap 10. Thus, in actual use, inductors with different turns ratios can be set according to different heat dissipation conditions of the environment, realizing differentiated design.

[0023] The inductor in this embodiment will be described in detail below with specific examples:

[0024] In one example, such as Figure 1 As shown, there are two winding posts 23, and the number of turns of coil 1 on the two winding posts 23 is different. The two winding posts 23 are the first winding post 231 and the second winding post 232. The number of turns of coil 1 wound on the first winding post 231 is greater than the number of turns of coil 1 wound on the second winding post 232, and the air gap 10 on the second winding post 232 is smaller than the air gap 10 on the first winding post 231.

[0025] Specifically, this embodiment provides an inductor. The magnetic core 2 includes an upper base plate 21, a lower base plate 22, two winding posts 23, and two non-winding posts 24. The two winding posts 23 are a first winding post 231 and a second winding post 232, respectively. The first winding post 231 has a first coil 11, and the second winding post 232 has a second coil 12. The number of turns of the first coil 11 is greater than the number of turns of the second coil 12, thereby increasing the magnetic field strength on the first winding post 231. The first winding post 231 includes a first air gap 101, and the second winding post 232 includes a second air gap 102. The first air gap 101 is larger than the second air gap 102, thereby increasing the magnetic reluctance on the first winding post 231. Under the combined effect of the number of turns of the first coil 11 on the first winding post 231 and the first air gap 101, the value of the first inductance formed by the first winding post 231 and the first coil 11 is relatively close to the value of the second inductance formed by the second winding post 232 and the second coil 12.

[0026] In some examples, the first winding post 231 forms a first inductance with the coil 1, and the second winding post 232 forms a second inductance with the coil 1, with the inductance values ​​of the first and second inductances being the same.

[0027] This embodiment provides the following: Figure 2 The inductor shown has the same number of turns for the first coil 11 on the first winding post 231 as the number of turns for the second coil 12 on the second winding post 232, and the air gap 10 on the first winding post 231 and the second winding post 232 is the same size. Assuming... Figure 2 In the inductor shown, the turns ratio of the first coil 11 and the second coil 12 is 3:3, while in this embodiment... Figure 1 The inductor shown has a turns ratio of 5:3 for the first coil 11 and the second coil 12. Simulation calculations are performed on the two inductors with the two turns ratios to calculate the core loss of the inductor 2. Figure 3 As shown, it can be seen that in the case of Figure 2 In the inductors with the same turns ratio, increasing the number of turns on a certain winding post 23 and increasing the air gap 10 significantly reduced the core loss. Copper loss, which is the power consumed by the resistance of the primary and secondary windings when current flows through them, confirms that increasing the number of turns on a certain winding post 23 and increasing the air gap 10 increases copper loss. This further confirms the correctness of the inventor's theory.

[0028] Optionally, the number of winding posts 23 is two, and the two winding posts 23 and the two non-winding posts 24 are arranged in a row, which gives a specific arrangement of the winding posts 23 and the non-winding posts 24.

[0029] In another example, such as Figure 4As shown, there are two non-wound posts 24, and multiple wound posts 23 are located between the two non-wound posts 24. The coils 1 on the multiple wound posts 23 are configured such that the magnetic flux formed by the coils 1 on the multiple wound posts 23 cancels each other out. That is, the magnetic flux formed by the coils 1 on the multiple wound posts 23 on the two non-wound posts 24 can cancel each other out. In this way, the cross-sectional area of ​​the non-wound posts 24 can be smaller than the cross-sectional area of ​​the wound posts 23. Reducing the volume of the non-wound posts 24 can not only reduce the magnetic loss of the magnetic core 2, but also improve the integration density of the inductor and reduce the volume of the inductor. Figure 4 The number of winding posts 23 shown is merely an example and is not intended to limit the number of winding posts 23 in the accompanying drawings.

[0030] In another example, the number of winding posts 23 can be three or more.

[0031] In this embodiment, the magnetic reluctance of the non-wound post 24 is less than that of the wound post 23. That is to say, there is no air gap 10 on the side post in this embodiment.

[0032] In this embodiment, the winding is wound on the winding posts 23, causing the current to generate magnetic fluxes of opposite directions and equal magnitudes on the two winding posts 23. Since both winding posts 23 have identical air gaps 10, while the non-winding posts 24 do not, the magnetic fluxes from the two winding posts 23 cancel each other out on the non-winding posts 24. This reduces the cross-sectional area of ​​the two non-winding posts 24, thereby reducing the volume of the magnetic core 2. Compared to inductors with larger cross-sectional areas, this reduces core 2 losses and improves circuit efficiency. Furthermore, reducing the cross-sectional area of ​​the non-winding posts 24 does not obstruct heat dissipation from the winding posts 23.

[0033] On the other hand, depending on the actual heat dissipation or the symmetry of the circuit parameters, the number of turns and the side posts can also be adjusted differently. Considering the different actual heat dissipation of the two integrated inductors, their respective optimizations can be carried out to maximize the utilization of the magnetic element coil 1 and magnetic core 2.

[0034] It is worth mentioning that, in order to highlight the innovative aspects of this invention, no units that are not closely related to solving the technical problems proposed by this invention have been introduced in this embodiment. However, this does not mean that there are no other units in this embodiment.

Claims

1. An inductor, characterized in that, include: Multiple coils and magnetic cores; The magnetic core includes: an upper base plate and a lower base plate arranged in parallel, a plurality of winding posts located between the upper base plate and the lower base plate and wound by the plurality of coils, and at least one non-winding post disposed between the upper base plate and the lower base plate; The coils on at least two of the winding posts have different numbers of turns and the magnetic flux generated by the current in the coils is in opposite directions. At least two of the winding posts with different numbers of turns each have an air gap, and the size of the air gap on each winding post is different. The number of turns of the coil on the two winding posts is different, and the two winding posts are the first winding post and the second winding post; The number of turns of the coil wound on the first winding post is greater than the number of turns of the coil wound on the second winding post, and the air gap on the second winding post is smaller than the air gap on the first winding post.

2. The inductor according to claim 1, characterized in that, The first winding post and the coil form a first inductance, and the second winding post and the coil form a second inductance. The first inductor and the second inductor have the same inductance value.

3. The inductor according to claim 1, characterized in that, The air gap is located at a position away from the upper base plate and the lower base plate of the winding post, and each winding post is connected to the upper base plate and the lower base plate.

4. The inductor according to claim 1 or 3, characterized in that, The air gap can be a single-segment air gap or a multi-segment air gap.

5. The inductor according to claim 1, characterized in that, There are two non-wound posts, and the plurality of winding posts are located between the two non-wound posts; The coils on the plurality of winding posts are configured such that the magnetic fluxes formed by the two non-winding posts cancel each other out.

6. The inductor according to claim 5, characterized in that, The number of winding posts is two, and the two winding posts and the two non-winding posts are arranged in a row.

7. The inductor according to claim 1, characterized in that, The non-winding post, the winding post, the upper base plate, and the lower base plate are integrally formed.

8. The inductor according to claim 1, characterized in that, The materials of the magnetic core include ferrite, amorphous, magnetic powder core or silicon steel.

9. The inductor according to claim 1, characterized in that, The magnetic reluctance of the non-wound post is less than that of the wound post.

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