Coupling inductor adjusting method, coupling inductor and electronic equipment

Abstract

The invention relates to the technical field of magnetic devices, and discloses a coupling inductor adjusting method, a coupling inductor and electronic equipment, the coupling inductor comprises magnetic cores, the two magnetic cores are oppositely arranged, and each magnetic core comprises a main magnet and winding middle columns arranged on the main magnet at intervals; the winding areas are arranged between the two magnetic cores at intervals, the winding middle columns and air gap pieces used for forming middle air gaps are arranged in the winding areas, and the air gap pieces are arranged between the winding middle columns of the two magnetic cores and connected with the winding middle columns respectively; at least one special-shaped winding coil is configured in the winding area, and is wound on the winding middle column; the leakage magnets are connected to the top end of the main magnet, and a top air gap is formed between the leakage magnets of the two magnetic cores. The copper loss of the coupling inductor is reduced, and the comprehensive performance of the coupling inductor is improved.

Description

Technical Field

[0001] This application relates to the technical field of magnetic devices, and particularly to a method for adjusting a coupled inductor, a coupled inductor, and an electronic device. Background Art

[0002] With the popularization and rapid development of electronic products, inductors are widely used in modern society. As an essential electronic component, it has various structures, and the coupled inductor is one of them. The coupled inductor can improve the load response speed of the DC-DC converter while minimizing leakage inductance. In related technologies, the coupled inductor is usually used in the DC-DC converter to provide a DC voltage output. However, for the ordinary coil of the traditional coupled inductor, the copper loss of the coils on both sides of the air gap is affected by the leakage magnetic flux, and the eddy current effect increases, resulting in an increase in copper loss, which in turn causes the inductor to heat up, increases the coil resistance, and reduces the inductor efficiency. This situation needs to be changed. Summary of the Invention

[0003] In view of this, this application provides a method for adjusting a coupled inductor, a coupled inductor, and an electronic device to reduce the loss of the coupled inductor and improve the comprehensive performance of the coupled inductor.

[0004] To achieve the above object, according to the first aspect, the technical solution adopted is:

[0005] A coupled inductor, comprising:

[0006] Magnetic cores, two of the magnetic cores are arranged opposite to each other, and each magnetic core includes a main magnet and winding middle columns arranged at intervals on the main magnet;

[0007] A winding area, arranged at intervals between the two magnetic cores, the winding area includes the winding middle columns and air gap sheets for forming an intermediate air gap, the air gap sheets are arranged between the winding middle columns of the two magnetic cores and are respectively connected to the winding middle columns;

[0008] An irregular winding coil, at least one of the irregular winding coils is arranged in the winding area and wound around the winding middle columns;

[0009] Leakage magnetic bodies, connected to the top ends of the main magnets, and a top air gap is formed between the leakage magnetic bodies of the two magnetic cores.

[0010] This application is further configured such that: one of the irregular winding coils is arranged in each winding area, and the outer wall contour of the irregular winding coil is normally distributed in the first direction and / or

[0011] the second direction along the axis of the winding middle column between the two magnetic cores, wherein the first direction is the extending direction of the upper and lower ends of the main magnet, and the second direction is perpendicular to the first direction.

[0012] The present application is further configured such that: within the winding region, the inner diameter and outer diameter of the special-shaped winding coil near the air gap sheet are respectively greater than the inner diameter and outer diameter of the coil away from the air gap sheet, or the inner diameter and outer diameter of the special-shaped winding coil near the main magnet are respectively smaller than the inner diameter and outer diameter of the coil near the air gap sheet.

[0013] The present application is further configured such that: two of the special-shaped winding coils are arranged within each winding region, and the two special-shaped winding coils are spaced apart by a set distance with respect to the air gap sheet along the axis of the winding middle column.

[0014] The present application is further configured such that: two of the special-shaped winding coils are arranged within each winding region, and the air gap sheet within the winding region is provided with an air gap avoidance region, and the two special-shaped winding coils are arranged outside the air gap avoidance region along the axis of the winding middle column.

[0015] The present application is further configured such that: the leakage magnet includes a main body portion and an adjustment portion provided on one side of the main body portion, the two ends of the main body portion are flush with the main magnet, and the adjustment portions of the two leakage magnets are arranged opposite to each other.

[0016] The present application is further configured such that: the two adjustment portions horizontally extend face to face along the axis direction of the winding middle column to adjust the size of the top air gap.

[0017] The present application is further configured such that: the two magnetic cores are designed in a UU-shaped structure, the preparation material of the magnetic cores includes manganese-zinc ferrite material, and the special-shaped winding coil includes a flat-shaped coil.

[0018] According to the second aspect, the technical solution adopted is:

[0019] A coupling inductor adjustment method, applied to the coupling inductor described in any of the above embodiments, includes:

[0020] Setting target parameters of the coupling inductor, the target parameters including a target inductance and a target leakage inductance;

[0021] Obtaining an average value of the initial top air gap of the coupling inductor;

[0022] Based on the average value of the initial top air gap, obtaining a target value of the middle air gap of the air gap sheet;

[0023] Based on the target value of the middle air gap of the air gap sheet, obtaining a target value of the top air gap of the coupling inductor;

[0024] Verify the actual parameters of the coupled inductor in combination with the target value of the middle air gap and the target value of the top air gap until the actual parameters become the target parameters.

[0025] This application is further configured such that: obtaining the target value of the middle air gap of the air gap sheet based on the average value of the initial top air gap includes:

[0026] Select the initial value of the middle air gap and superimpose a first vector value on the initial value of the middle air gap until the actual inductance of the coupled inductor becomes the target inductance.

[0027] This application is further configured such that: obtaining the target value of the top air gap of the coupled inductor based on the target value of the middle air gap of the air gap sheet includes:

[0028] Select the initial value of the top air gap and superimpose a second vector value on the initial value of the top air gap until the actual leakage inductance of the coupled inductor becomes the target leakage inductance.

[0029] According to the third aspect, the technical solution adopted is:

[0030] An electronic device includes the coupled inductor described in any of the above embodiments.

[0031] In summary, compared with the prior art, this application discloses a coupled inductor and an electronic device. The two magnetic cores of the coupled inductor are arranged opposite to each other. The magnetic core includes a main magnet and winding middle columns arranged at intervals on the main magnet. Among them, winding areas are arranged at intervals between the two magnetic cores. The air gap sheets in the winding areas are arranged between the winding middle columns of the two magnetic cores and are respectively connected to the winding middle columns to form a middle air gap. In addition, at least one special-shaped winding coil is arranged in the winding area and wound around the winding middle columns. A top air gap is formed between the leakage magnets of the two magnetic cores. That is, through the above settings, the coupled magnetic flux and leakage magnetic flux of the coupled inductor are separated, a distributed air gap structure is constructed, the magnetic loss of the coupled inductor is reduced, and the effects of accurately controlling the inductance (OCL) and leakage inductance (SCL) can be achieved, improving the comprehensive performance of the coupled inductor. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] In order to more clearly illustrate the technical solutions in the embodiments of this application, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are only some embodiments of this application. For those skilled in the art, without creative efforts, other drawings can be obtained based on these drawings.

[0033] Figure 1 is a three-dimensional structural schematic diagram of the first coupled inductor of this application;

[0034] Figure 2It is a top - view structural schematic diagram of the first kind of coupled inductor of the present application;

[0035] Figure 3 It is a sectional - view structural schematic diagram of the first kind of coupled inductor of the present application;

[0036] Figure 4 It is a three - dimensional structural schematic diagram of the first kind of special - shaped winding coil of the present application;

[0037] Figure 5 It is a three - dimensional structural schematic diagram of the second kind of coupled inductor of the present application;

[0038] Figure 6 It is a top - view structural schematic diagram of the first kind of coupled inductor of the present application;

[0039] Figure 7 It is a schematic diagram of the working temperature distribution of the coupled inductor of the present application;

[0040] Figure 8 It is a flowchart of the method for adjusting the coupled inductor of the present application. Detailed implementation manners

[0041] Here, exemplary embodiments will be described in detail, and the examples are shown in the drawings. When the following description refers to the drawings, unless otherwise indicated, the same numbers in different drawings represent the same or similar elements. The implementation manners described in the following exemplary embodiments do not represent all implementation manners consistent with the present application. On the contrary, they are merely examples of devices and methods consistent with some aspects of the present application as detailed in the appended claims.

[0042] It should be noted that in this text, the term "including", "comprising" or any other variant thereof is intended to cover non - exclusive inclusion, so that a process, method, article or device including a series of elements not only includes those elements, but also includes other elements not expressly listed, or further includes elements inherent to such process, method, article or device. Without further limitation, an element defined by the statement "including one..." does not exclude the presence of another identical element in the process, method, article or device including that element. In addition, components, features, elements with the same name in different embodiments of the present application may have the same meaning or different meanings, and their specific meanings need to be determined according to their explanations in the specific embodiments or further in combination with the context of the specific embodiments.

[0043] It should be understood that the specific embodiments described herein are only used to explain the present application and are not used to limit the present application.

[0044] In the following description, suffixes such as "module", "component", or "unit" used to represent elements are only for the convenience of explaining the present application, and have no specific meaning in themselves. Therefore, "module", "component", or "unit" can be used interchangeably.

[0045] In the description of the present application, it should be noted that the orientation or positional relationship indicated by terms such as "upper", "lower", "left", "right", "inner", "outer", etc. is based on the orientation or positional relationship shown in the drawings. It is only for the convenience of describing the present application and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore should not be construed as a limitation to the present application. In addition, the terms "first", "second", and "third" are only used for descriptive purposes and should not be construed as indicating or implying relative importance.

[0046] The technical solution shown in the present application will be described in detail below through specific embodiments. It should be noted that the description order of the following embodiments does not limit the priority order of the embodiments.

[0047] Please refer to Figures 1 to 6 , the coupled inductor of the embodiment of the present application includes a magnetic core 1, a winding area 2, a special-shaped winding coil 4, and a magnetic leakage body 5.

[0048] In the specific implementation process, the two magnetic cores 1 of the coupled inductor are arranged opposite to each other. Among them, each magnetic core 1 includes a main magnet 11 and winding middle columns 12 arranged at intervals on the main magnet 11.

[0049] Furthermore, the winding area 2 is arranged at intervals between the two magnetic cores 1. The winding area 2 includes winding middle columns 12 and air gap sheets 3, and the air gap sheets 3 are arranged between the winding middle columns 12 of the two magnetic cores 1 and are respectively connected to the winding middle columns 12.

[0050] Among them, at least one special-shaped winding coil 4 is arranged in the winding area 2 and wound around the winding middle column 12, and the magnetic leakage body 5 is connected to the top of the main magnet 11, and a top air gap is formed between the magnetic leakage bodies 5 of the two magnetic cores 1.

[0051] Based on the coupled inductor designed with this structure, the air gap sheet 3 forms an intermediate air gap to effectively control the magnetic saturation degree of the coupled inductor, and optimizes the magnetic field distribution of the coupled inductor by being respectively connected to the winding middle column 12 in the winding area 2, reducing the influence of high-frequency eddy currents in the winding area 2, thereby reducing the copper loss of the device and improving the working efficiency of the coupled inductor. The top air gap formed between the leakage magnetic bodies 5 of the two magnetic cores 1 can further uniform the magnetic field distribution, enabling the leakage magnetic flux of the coupled inductor to be separated from the mutual magnetic flux from the beginning and directly enter the leakage magnetic body 5 at the top of the main magnetic body 11. That is, based on the design of the top air gap, the leakage magnetic flux will not be overly concentrated in the winding area 2, but is directly guided to the leakage magnetic body 5 at the top of the main magnetic body 11, ensuring a more uniform magnetic field distribution to avoid local overheating. Then, since the leakage magnetic flux does not accumulate in the winding area 2, the influence of the leakage magnetic flux on the special-shaped winding coil 4 is reduced, thereby reducing the eddy current effect and additional copper loss, improving the overall inductance efficiency, and reducing the energy loss caused by the leakage magnetic flux. The coupled inductor of this embodiment optimizes the magnetic flux path of the device through the distributed air gap structure design of this intermediate air gap and top air gap, can precisely control the effects of the open circuit inductance (OCL, Open Circuit Inductance) and short circuit inductance (SCL, Short Circuit Inductance), reduces the magnetic loss and copper loss of the device, improves the mechanical stability of the device, and makes the overall performance of the device better, especially suitable for high power density and high efficiency DC-DC converters and other electronic devices.

[0052] Optionally, the air gap sheet 3 is connected to the winding middle columns 12 of the two magnetic cores 1 by an adhesive fixing method, providing additional structural support for the coupled inductor, enhancing the mechanical strength between the magnetic cores 1, and reducing the influence of vibration and external force impact on the performance of the coupled inductor.

[0053] It should be noted that the air gap sheet 3 is arranged between the winding middle columns 12 of the two magnetic cores 1. Then, the size of the intermediate air gap of the coupled inductor formed by the air gap sheet 3 can be regarded as the thickness size of the air gap sheet 3. The thickness of the air gap sheet 3 in the embodiment of the present application is adjustable, that is, the size of the intermediate air gap of the coupled inductor is adjustable.

[0054] For the sake of brief description, hereinafter, the open circuit inductance (OCL, Open Circuit Inductance) is simply referred to as the inductance (OCL), and the short circuit inductance (SCL, Short Circuit Inductance) is simply referred to as the leakage inductance (SCL).

[0055] In one embodiment, the two magnetic cores 1 can be designed in a UU-shaped structure, that is, two winding middle columns 12 can be arranged at intervals on the main magnet 11 of each magnetic core 1, and the main magnet 11 and the winding middle column 12 form a U-shaped structure. Thus, the coupled inductor of the UU-shaped structure enables the main magnets 11 of the two magnetic cores 1 to cooperate more closely, forming a good magnetic flux closed loop, improving the mutual inductance coupling efficiency, which helps to reduce the leakage inductance (SCL), enabling the DC-DC converter to respond faster when the load changes, improving the dynamic performance, and the coupled inductor of the UU-shaped structure combined with the top air gap enables the leakage magnetic flux to be better guided to the leakage magnet 5 at the top of the main magnet 11, rather than forming a local high magnetic field density in the winding area 2, reducing the eddy current loss. Moreover, the coupled inductor of the UU-shaped structure has stronger symmetry and less deformation when affected by external forces compared with the E-I type or other open magnetic core structures, and is particularly suitable for application scenarios that require high reliability such as automotive electronics and server power supplies.

[0056] In one embodiment, the preparation material of the magnetic core 1 includes manganese-zinc ferrite material. The coupled inductor constructed based on the magnetic core 1 of the manganese-zinc ferrite material has a high magnetic permeability, can provide a stronger magnetic flux coupling ability, enables the coupled inductor to maintain a high mutual inductance within the operating frequency range, and improves the energy transfer efficiency. Moreover, manganese-zinc ferrite has a low core loss in the medium and low frequency range (1 kHz - 1 MHz), and has lower loss in the range of 100 kHz - 500 kHz compared with nickel-zinc ferrite (Ni-Zn Ferrite). Then, due to the reduction of the core loss, the overall temperature rise of the coupled inductor is reduced, thereby improving the system reliability and being applicable to high-efficiency power electronic devices. In addition, the saturation magnetic flux density of manganese-zinc ferrite is relatively high, and it can maintain good magnetic properties under a large current, avoiding the magnetic core from entering the saturation state in advance. Combining the aforementioned distributed air gap structure design can further optimize the magnetic flux distribution, reduce the local heating problem, and enable the coupled inductor to remain stable for a long time under high power density applications.

[0057] It should be noted that in this embodiment, an X-Y-Z space coordinate system is constructed. Taking Figure 1 、 3 as an example, the Z-axis direction can be regarded as the first direction, the X-axis direction can be regarded as the second direction, and the Y-axis direction can be regarded as the third direction. The first direction can also be regarded as the extension direction of the upper and lower ends of the main magnet 11, the second direction can also be regarded as the extension direction of the front and back sides of the main magnet 11, and the third direction can also be regarded as the extension direction of the left and right sides of the main magnet 11. Of course, this embodiment is not limited to this. X-Y-Z can also be any other three mutually perpendicular directions in space according to actual needs, which will not be elaborated here.

[0058] In the specific implementation process, in combination with Figures 1 to 4, one special-shaped winding coil 4 can be arranged in each winding area 2. The outer wall contour of the special-shaped winding coil 4 is normally distributed in the first direction and / or the second direction along the axis of the winding middle column 12 between the two magnetic cores 1, that is, the outer wall contour line of the special-shaped winding coil 4 is a normal distribution curve on the plane coordinate system constructed with the axis of the winding middle column 12 as the horizontal axis and the first direction and / or the second direction as the vertical axis.

[0059] Therefore, it can also be considered that in the winding area 2, the inner coil diameter and the outer coil diameter of the special-shaped winding coil 4 close to the air gap sheet 3 are respectively greater than those of the special-shaped winding coil 4 far from the air gap sheet 3, or the inner coil diameter and the outer coil diameter of the special-shaped winding coil 4 close to the main magnet 11 are respectively less than those of the special-shaped winding coil 4 close to the air gap sheet 3.

[0060] For the coupled inductor of this embodiment, the normal distribution of the outer wall contour of the special-shaped winding coil 4 makes the magnetic field distribution closer to the ideal state, reduces the high magnetic flux density area, thereby reducing local saturation and core loss, and reducing the skin effect and proximity effect during high-frequency operation. Moreover, since the special-shaped winding coil 4 in the winding area 2 matches the magnetic field distribution, the magnetic energy product (B·H) per unit volume is higher, and the core size can be reduced under the same inductance, realizing a design with higher power density. Combining with the UU-shaped structure and the distributed air gap structure design, the entire device is more suitable for the application of miniaturized and high-efficiency electronic devices, that is, it optimizes the magnetic flux path of the device, can accurately control the effects of the inductance (OCL) and leakage inductance (SCL), and reduces the magnetic loss and copper loss of the device.

[0061] It can be understood that for the coupled inductor in the related art, when the winding is close to the air gap, it will be affected by strong leakage magnetic flux, resulting in an increase in the local magnetic flux density, causing additional copper loss and eddy current effect. However, the structural design of the special-shaped winding coil 4 of the coupled inductor in this embodiment can adjust and adapt the distance between the special-shaped winding coil 4 at the air gap sheet 3 and the air gap sheet 3, so that the coil winding of the coupled inductor is far from the high leakage magnetic area, achieving the purpose of avoiding the air gap.

[0062] Preferably, the middle air gap formed by the air gap sheet 3 is denoted as L1. The size of L1 can be adjusted according to the specific thickness of the air gap sheet 3 or the stacking of multiple air gap sheets 3. By adjusting L1, the magnetic flux density and magnetic field distribution of the coupled inductor can be precisely controlled, ensuring that the coupled inductor does not enter the saturation state prematurely. At the same time, the leakage flux path is optimized, and more flexible design options can also be provided, optimizing the performance of the coupled inductor in different application scenarios. For example, the larger L1 is, the greater the magnetic resistance is, and the lower the overall inductance value is, but the linearity is improved, which is suitable for high-current applications. The smaller L1 is, the smaller the magnetic resistance is, and the greater the overall inductance value is, which is suitable for applications with higher requirements for inductance value. Moreover, the set middle air gap can be adjusted by a single air gap sheet 3 or a stacked air gap sheet 3. Then, in the mass production process of the coupled inductor, consistency can be ensured through different combination methods, reducing production errors and improving product reliability.

[0063] Optionally, the preparation material of the air gap sheet 3 includes but is not limited to PI film. The PI film has excellent heat resistance and is suitable for DC-DC converters and other power electronic devices operating in high-power and high-temperature environments. Moreover, the PI film has high tensile strength and tear resistance, enabling the air gap sheet 3 to remain stable during long-term operation and not easily deformed or ruptured due to mechanical stress or thermal stress. At the same time, the PI film has high dielectric strength, which can effectively prevent leakage or breakdown problems in high-frequency working environments and improve the reliability of the coupled inductor.

[0064] The preparation material of the air gap sheet 3 can also include PET film or ceramic-filled composite material.

[0065] In one embodiment, the leakage magnetic body 5 includes a main body portion 51 and an adjusting portion 52 provided on one side of the main body portion 51. The two ends of the main body portion 51 are flush with the main magnet 11, and the adjusting portions 51 of the two leakage magnetic bodies 5 are arranged opposite to each other. Thus, a top air gap (denoted as L2) is formed between the adjusting portions 51 of the two leakage magnetic bodies 5, and the size of L2 can be adjusted according to the distance between the two adjusting portions 51.

[0066] Optionally, the two adjusting portions 51 extend horizontally face to face along the axis direction of the winding middle column 12 to adjust the size of L2. Specifically, by extending the horizontal length of the adjusting portion 51 face to face along the axis direction of the winding middle column 12, L2 correspondingly becomes smaller. Thus, the leakage flux of the coupled inductor can be reduced, the mutual inductance coefficient can be increased, the leakage inductance (SCL) can be reduced, and the efficiency of the coupled inductor can be improved.

[0067] It can be understood that when the side of the adjusting portion 51 is flush with the inner wall of the main magnet 11, the top air gap is the largest. Among them, the maximum top air gap can be 7.88 mm.

[0068] Preferably, the adjusting portions 51 of the two leakage magnetic bodies 5 are parallel to each other.

[0069] In one embodiment, with reference to Figure 5 and Figure 6 , two shaped winding coils 4 are arranged in each winding area 2. The two shaped winding coils 4 are arranged along the axis of the winding middle column 12 and are kept at a set separation (denoted as L3) relative to the air gap sheet 3. Thus, through the set separation, the shaped winding coils 4 are relatively far away from the air gap sheet 3, achieving the purpose of air gap avoidance, thereby reducing the eddy current effect, lowering the loss, and improving the coupling inductance efficiency.

[0070] In the specific implementation process, two shaped winding coils 4 are arranged in each winding area 2, and the air gap sheet 3 in the winding area 2 is provided with an air gap avoidance area 6. The two shaped winding coils 4 are arranged outside the air gap avoidance area 6 along the axis of the winding middle column 12. Thus, through the design of the air gap avoidance area 6, the shaped winding coils 4 are relatively far away from the air gap sheet 3, achieving the purpose of air gap avoidance.

[0071] Preferably, the size of the set separation is the same as the width of the air gap avoidance area 6.

[0072] In one embodiment, the coupling inductor further includes a connection pin 7. The connection pin 7 is arranged at the end of the shaped winding coil 4 and is integrally connected with the shaped winding coil 4. Then, the integrally connected connection pin 7 can reduce the contact resistance, improve the current transmission efficiency, lower the energy loss, avoid problems such as virtual soldering and open circuit that may occur at the welding point, avoid mechanical stress damage, and improve the long-term reliability of the coupling inductor.

[0073] Preferably, the connection pin 7 is kept parallel to the end faces of the upper and lower ends of the main magnet 11, making the connection pin 7 more stable during installation or welding, not prone to tilting or breaking. And a functional groove 13 is provided on the main magnet 11 at the position corresponding to the connection pin 7. The groove profile of the functional groove 13 is adapted to the connection pin 7, so as to have an elastic buffer space between the connection pin 7 and the main magnet 11, enabling the connection pin 7 to be partially embedded in the main magnet 11, improving the fixing property, preventing displacement or loosening caused by vibration or external force. And, due to the corresponding cooperation between the connection pin 7 and the functional groove 13, the displacement error of the pin during welding or assembly can be reduced, thereby optimizing the current path and improving the electrical conductivity.

[0074] In one embodiment, the shaped winding coil 4 includes a flat-shaped structure coil. The flat-shaped structure coil can expand the winding area of the shaped winding coil 4. Compared with the traditional circular coil, it can provide a larger effective magnetic flux path, thereby enhancing the magnetic coupling. And the larger winding area helps to increase the mutual inductance and improve the working efficiency of the coupling inductor, especially suitable for high-power and high-frequency application environments. And the flat-shaped structure coil can better adapt to the compact space requirements, improve the device integration degree. And, the flat-shaped structure coil has a larger surface area, which helps to dissipate heat faster and reduce the local overheating problem.

[0075] Combined with the structural design of the aforementioned special-shaped winding coil 4, the coupled inductor of the embodiment of the present application optimizes the magnetic flux path of the device, reduces the copper loss of the device, and improves the mechanical stability of the device, making the overall performance of the device better. It is particularly suitable for high power density and high efficiency DC-DC converters and other electronic devices, and as Figure 7 shown, during the operation of the coupled inductor, compared with the traditional inductor, the dispersion degree of the highest / lowest temperature is lower, the overall working heat generation is lower, and there is no local overheating problem. The copper loss of the coupled inductor is 0.2605w, enabling the coupled inductor to operate stably and efficiently for a long time under high power density applications.

[0076] Continuing to refer to Figure 8 , the present application also discloses a method for adjusting a coupled inductor. The method for adjusting the coupled inductor is based on the coupled inductor of any of the above embodiments to optimize the performance parameters of the coupled inductor, reduce the loss of the coupled inductor, and improve the comprehensive performance of the coupled inductor. Specifically, the method for adjusting the coupled inductor includes:

[0077] S201, setting the target parameters of the coupled inductor, where the target parameters include the target inductance and the target leakage inductance.

[0078] In one embodiment, the target inductance (OCL) of the coupled inductor includes 2uH ± 10%, and the target leakage inductance (SCL) includes 1.4uH ± 10%.

[0079] Preferably, the target inductance is 2uH, and the target leakage inductance is 1.4uH.

[0080] S202, obtaining the average value of the initial top air gap of the coupled inductor.

[0081] In the specific implementation process, when the side of the adjusting part 51 is flush with the inner wall of the main magnet 11, it is the maximum value of the top air gap. Then, the average value of the initial top air gap of the coupled inductor includes 1 / 2 times the maximum value of the top air gap.

[0082] In one embodiment, the maximum value of the top air gap includes 7.88mm, and the average value of the initial top air gap is 7.88 / 2mm, that is, 3.94mm.

[0083] S203, obtaining the target value of the middle air gap of the air gap sheet 3 based on the average value of the initial top air gap.

[0084] In the specific implementation process, obtaining the target value of the middle air gap of the air gap sheet 3 includes: selecting the initial value of the middle air gap, and adding a first vector value to the initial value of the middle air gap until the actual inductance of the coupled inductor is the target inductance.

[0085] Among them, the first vector value includes 0.1mm.

[0086] In one embodiment, the initial value of the middle air gap can start from 0. Then, based on the initial average value of the top air gap being 3.94 mm, the target value of the middle air gap of the air gap sheet 3 is obtained, that is, the first vector value is superimposed on the initial value of the middle air gap, such as 0.1, 0.2, 0.3, 0.4 mm..., until the actual inductance of the coupled inductor is the target inductance, so as to obtain the target value of the middle air gap.

[0087] Preferably, the first vector value is superimposed on the initial value of the middle air gap until the actual inductance of the coupled inductor is 1.96 uH, that is, within the target inductance range, and the target value of the middle air gap is obtained as 0.3 mm.

[0088] S204. Based on the target value of the middle air gap of the air gap sheet 3, obtain the target value of the top air gap of the coupled inductor.

[0089] It can be understood that the size of the top air gap of the coupled inductor in the embodiment of the present application has a very small impact on its inductance (OCL), while having a very large impact on its leakage inductance (SCL).

[0090] In the specific implementation process, obtaining the target value of the top air gap of the coupled inductor includes: selecting the initial value of the top air gap, and superimposing the second vector value on the initial value of the top air gap until the actual leakage inductance of the coupled inductor is the target leakage inductance.

[0091] Among them, the second vector value includes 0.5 mm.

[0092] In one embodiment, the initial value of the top air gap can start from 4 mm. Then, based on the target value of the aforementioned middle air gap being 0.3 mm, the target value of the top air gap is obtained, that is, the second vector value is superimposed on the initial value of the top air gap, such as 4.5, 5, 5.5, 6, 6.5, 7 mm..., until the actual leakage inductance of the coupled inductor is the target leakage inductance, so as to obtain the target value of the top air gap.

[0093] Preferably, the second vector value is superimposed on the initial value of the top air gap until the actual leakage inductance of the coupled inductor is 1.41 uH, that is, within the target leakage inductance range, and the target value of the top air gap is obtained as 5.5 mm.

[0094] S205. Combine the target value of the middle air gap and the target value of the top air gap to verify the actual parameters of the coupled inductor until the actual parameters are the target parameters.

[0095] Optionally, combine the target value of the middle air gap being 0.3 mm and the target value of the top air gap being 5.5 mm to verify the actual inductance and leakage inductance of the coupled inductor. If the actual inductance and leakage inductance of the coupled inductor are not within their target inductance and leakage inductance ranges, repeat the above steps until the actual inductance and leakage inductance of the coupled inductor are the target inductance and leakage inductance.

[0096] Therefore, through this systematic coupled inductor regulation method, the coupled inductor with target parameters can be obtained efficiently and accurately. Moreover, through the distributed air gap structure design of the middle air gap and the top air gap, the magnetic flux path of the device is optimized, the copper loss of the device is reduced, and the mechanical stability of the device is improved, making the overall performance of the device better. It is particularly suitable for high power density and high efficiency DC-DC converters and other electronic devices.

[0097] This application also discloses an electronic device, including the coupled inductor as described in any of the above embodiments. For the other working principles and processes of the electronic device in this embodiment, refer to the description of the coupled inductor in the foregoing embodiments of this application, which will not be elaborated here.

[0098] The coupled inductor and the electronic device provided in this application have been introduced in detail above. Specific examples are used in this article to elaborate on the principles and implementation manners of this application. It should be noted that in this application, the descriptions of each embodiment have their own focuses. For the parts not elaborated or recorded in a certain embodiment, reference can be made to the relevant descriptions of other embodiments.

[0099] The above are only the preferred embodiments of this application, and do not limit the patent scope of this application accordingly. The technical features of the technical solutions of this application can be combined arbitrarily. For the sake of brevity of description, not all possible combinations of the technical features in the above embodiments are described. Any equivalent structural or equivalent process transformation made by using the content of the specification and drawings of this application, or directly or indirectly applied in other related technical fields, as long as the combination of these technical features does not conflict, is similarly included in the patent protection scope of this application.

Claims

1. A coupled inductor, characterized in that, Comprising: A magnetic core, two of the magnetic cores are arranged oppositely, each magnetic core includes a main magnet, and winding middle columns arranged at intervals on the main magnet; A winding area, arranged at intervals between the two magnetic cores, the winding area includes the winding middle columns and air gap sheets for forming an intermediate air gap, the air gap sheets are arranged between the winding middle columns of the two magnetic cores and are respectively connected to the winding middle columns; A special-shaped winding coil, at least one special-shaped winding coil is arranged in the winding area and wound around the winding middle columns; A leakage magnetic body, connected to the top end of the main magnet, and a top air gap is formed between the leakage magnetic bodies of the two magnetic cores.

2. The coupled inductor according to claim 1, wherein One special-shaped winding coil is arranged in each winding area, and the outer wall contour of the special-shaped winding coil is normally distributed in the first direction and / or, The second direction along the axis of the winding middle column between the two magnetic cores, wherein the first direction is the extending direction of the upper and lower ends of the main magnet, and the second direction is perpendicular to the first direction.

3. The coupled inductor according to claim 1, characterized in that, In the winding area, the inner diameter and outer diameter of the special-shaped winding coil close to the air gap sheet are respectively greater than the inner diameter and outer diameter of the coil away from the air gap sheet, or the inner diameter and outer diameter of the special-shaped winding coil close to the main magnet are respectively less than the inner diameter and outer diameter of the coil close to the air gap sheet.

4. The coupled inductor according to claim 1, wherein Two special-shaped winding coils are arranged in each winding area, and the two special-shaped winding coils maintain a set separation relative to the air gap sheet along the axis of the winding middle column.

5. The coupled inductor according to claim 1, wherein Two special-shaped winding coils are arranged in each winding area, and the air gap sheet in the winding area is provided with an air gap avoidance area, and the two special-shaped winding coils are arranged outside the air gap avoidance area along the axis of the winding middle column.

6. The coupled inductor according to claim 1, wherein The leakage magnetic body includes a main body part and an adjusting part arranged on one side of the main body part, the two ends of the main body part are flush with the main magnet, and the adjusting parts of the two leakage magnetic bodies are arranged oppositely.

7. The coupled inductor according to claim 6, wherein The two adjusting parts horizontally extend face to face along the axis direction of the winding middle column to adjust the size of the top air gap.

8. The coupled inductor according to any one of claims 1 to 7, wherein The two magnetic cores are designed in a UU-shaped structure, the preparation material of the magnetic core includes a Mn-Zn ferrite material, and the special-shaped winding coil includes a flat-shaped structure coil.

9. A coupled inductor regulation method, applied to the coupled inductor according to any one of claims 1 to 8, characterized in that, Comprising: Setting target parameters of a coupling inductor, the target parameters including a target inductance and a target leakage inductance; Obtaining the average value of the initial top air gap of the coupling inductor; Based on the average value of the initial top air gap, obtaining the target value of the intermediate air gap of the air gap sheet; Based on the target value of the intermediate air gap of the air gap sheet, obtaining the target value of the top air gap of the coupling inductor; Combining the target value of the intermediate air gap and the target value of the top air gap to verify the actual parameters of the coupling inductor until the actual parameters are the target parameters.

10. The coupled inductor regulation method according to claim 9, wherein, The obtaining the target value of the intermediate air gap of the air gap sheet based on the average value of the initial top air gap includes: Selecting the initial value of the intermediate air gap, and superimposing a first vector value on the initial value of the intermediate air gap until the actual inductance of the coupling inductor is the target inductance.

11. The coupled inductor regulation method according to claim 10, wherein Obtaining the target value of the top air gap of the coupling inductor based on the target value of the middle air gap of the air gap sheet includes: Selecting an initial value of the top air gap and superimposing a second vector value on the initial value of the top air gap until the actual leakage inductance of the coupling inductor is the target leakage inductance.

12. An electronic device, characterized in that, The coupling inductor according to any one of claims 1 to 8 is included.

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