Single-phase two-in-one magnetic integrated BOOST boost inductor applied to high frequency and low loss
By using a combined magnetic core structure made of ferrite material in high-frequency magnetic integrated inductors, a mirror-symmetric "port" font structure is formed, and inductive windings are wound on the central column magnetic core, and the magnetic loss is reduced by using the isolation plate to solve the problem of The problems of medium and high-frequency iron loss and production and assembly difficulty in the prior art are achieved, and magnetic integrated inductors with high frequency and low loss and stable product quality are realized.
Patent Information
- Application Number
- CN202421062951.7
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-16
- Publication Date
- 2025-02-25
- Estimated Expiration
- 2034-05-16
AI Technical Summary
Existing magnetic integrated inductors have iron loss problems when applied at high frequency, resulting in high core loss. Due to the interaction of different materials, production and assembly are difficult and product quality is unstable.
Using a single-phase two-in-one magnetic integrated BOOST boost inductor, the cross-beam core, upper jaw core, lower jaw core and middle column core are all made of ferrite power material to form a mirror symmetry. The inductive winding is wound on the central column magnetic core to reduce magnetic loss by using the isolation plate.
It realizes high frequency and low loss magnetic integrated inductor, simplifies the production and assembly process, improves product quality stability, reduces magnetic loss and system ripple, and improves load inductance.
Smart Images
Figure CN222530168U_ABST
Abstract
Description
Technical Field
[0001] The utility model belongs to the technical field of magnetic integrated inductors, and in particular relates to a two-in-one magnetic integrated BOOST boost inductor applied to high frequency and low loss single-phase. Background Art
[0002] Magnetic components, as the core components of power electronic converters, are directly related to the power density and efficiency of the entire system. However, with the continuous development of power electronic technology, magnetic components have become a key constraint to further improve power density. In order to overcome this problem, magnetic integration technology came into being. By cleverly integrating multiple inductors together, the volume of the inductor is significantly reduced, thereby achieving cost reduction.
[0003] Currently, there are integrated inductor products on the market, which closely integrate two or more inductors through a common magnetic core. This design cleverly utilizes the mutual cancellation effect of magnetic flux, realizes the optimal distribution of magnetic flux on the common magnetic core, and then reduces the cross-sectional area of the common magnetic core. This not only greatly reduces the volume of magnetic components, realizes miniaturization and integration, but also improves the power density of power electronic converters, injecting new vitality into the development of power electronic technology.
[0004] However, this inductor structure has a large iron loss problem when used at high frequencies, resulting in high core loss. In order to reduce losses, it is usually necessary to select core materials with low high-frequency losses, but such materials are often expensive, making the cost-saving effect unsatisfactory. In addition, current magnetic integration solutions mostly use a combination of magnetic powder cores and ferrites or amorphous blocks. This combination involves two different materials, which brings considerable difficulty to production and assembly. This is because the physical and chemical properties of magnetic powder cores and ferrites or amorphous blocks are different. They are prone to interact during the production and assembly process, resulting in unstable product quality.
[0005] To this end, the utility model provides a high-frequency, low-loss single-phase two-in-one magnetically integrated BOOST boost inductor. Utility Model Content
[0006] In view of the above-mentioned problems existing in the prior art, the purpose of the utility model is to provide a high-frequency, low-loss single-phase two-in-one magnetic integrated BOOST boost inductor solution. The magnetic integration solution mostly adopts a combination of magnetic powder core and ferrite or amorphous block. This combination involves two different materials, which brings considerable difficulty to production and assembly. This is because the magnetic powder core and ferrite or amorphous block have different physical and chemical properties, and they are prone to interact with each other during the production and assembly process, resulting in unstable product quality.
[0007] The purpose of the utility model can be achieved through the following technical solutions:
[0008] A BOOST boost inductor for high-frequency and low-loss single-phase two-in-one magnetic integration includes a combined magnetic core, wherein the combined magnetic core is provided with a beam magnetic core, wherein upper jaw magnetic cores are provided on the left and right sides of the upper end of the beam magnetic core, and lower jaw magnetic cores are provided on the left and right sides of the lower end of the beam magnetic core, wherein a middle column magnetic core is provided between the upper jaw magnetic core and the lower jaw magnetic core on the left side of the beam magnetic core, and a middle column magnetic core is also provided between the upper jaw magnetic core and the lower jaw magnetic core on the right side of the beam magnetic core, wherein the combined magnetic core presents two mirror-symmetrical "mouth"-shaped magnetic core structures;
[0009] Inductance windings are symmetrically wound on both sides of the combined magnetic core, and the inductance windings are wound on the middle column magnetic cores on the corresponding sides, and isolation plates are provided between the inductance windings and the upper magnetic core and the lower magnetic core;
[0010] The crossbeam magnetic core, the upper jaw magnetic core, the lower jaw magnetic core and the middle column magnetic core are all made of ferrite power material.
[0011] As a further preferred technical solution of the utility model, the crossbeam magnetic core forms two inductors with the middle column magnetic core, upper jaw magnetic core, lower jaw magnetic core, middle column magnetic core and inductor winding on the left and right sides, and the current phase difference between the two inductors is 180°.
[0012] As a further preferred technical solution of the utility model, the central column magnetic core is formed by stacking a plurality of circular magnetic blocks which are bonded and fixed with epoxy glue, and a uniform air gap is provided between each magnetic block.
[0013] As a further preferred technical solution of the utility model, the air gap thickness is 0.13-0.5 mm
[0014] As a further preferred technical solution of the utility model, the ferrite power material used to make the crossbeam core, upper jaw core and lower jaw core is specifically a breathless power ferrite block core, and the crossbeam core, upper jaw core and lower jaw core are integrated block cores made of breathless power ferrite material.
[0015] As a further preferred technical solution of the utility model, the inductor winding is made of Litz stranded wire or Litz film-wrapped stranded wire.
[0016] As a further preferred technical solution of the utility model, the crossbeam magnetic core, the upper jaw magnetic core, the lower jaw magnetic core and the middle column magnetic core are all fixedly connected by applying a single-component epoxy resin glue.
[0017] As a further preferred technical solution of the utility model, the outer contour of the isolation plate is an elliptical runway shape, a rectangular through hole for clamping with the crossbeam magnetic core is opened in the center of the isolation plate, and circular through holes for clamping with the middle column magnetic core are opened on both sides of the rectangular through hole.
[0018] As a further preferred technical solution of the present invention, the isolation board is an epoxy FR4 board.
[0019] As described above, the utility model provides a high-frequency, low-loss single-phase two-in-one magnetic integrated BOOST boost inductor, which has the following beneficial effects:
[0020] 1. The utility model utilizes the above-mentioned one kind of high-frequency and low-loss single-phase two-in-one magnetic integrated BOOST boost inductor. Compared with the prior art, the combined magnetic cores are made of ferrite power material, the production and assembly are relatively simple, and the stability of product quality is guaranteed.
[0021] 2. The utility model utilizes the above-mentioned high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor. Compared with the prior art, each magnetic block is padded with uniform air gaps to achieve the air segmentation effect. The transformer segmentation air gap is to prevent magnetic saturation during operation. The air gap is the gap left at the intersection of the iron core. The role of the air gap is to reduce the magnetic permeability, which can avoid the magnetic core from producing magnetic saturation under large AC signals or DC bias.
[0022] Additional aspects and advantages of the present invention will be given in part in the following description, and in part will become apparent from the following description, or will be learned through the practice of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS
[0023] In order to more clearly illustrate the embodiments of the utility model or the technical solutions in the prior art, the drawings required for use in the embodiments or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the utility model. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative labor.
[0024] Figure 1 This is a schematic diagram of the structure of a high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor applied in the utility model application;
[0025] Figure 2 This is a schematic diagram of a combined magnetic core structure for a high-frequency, low-loss, single-phase two-in-one magnetically integrated BOOST boost inductor applied in the utility model;
[0026] Figure 3 This is a schematic diagram of the structure of an isolation board applied to a high-frequency, low-loss single-phase two-in-one magnetically integrated BOOST boost inductor applied in the utility model.
[0027] Summary of reference numerals and their descriptions:
[0028] 100. Combined magnetic core; 110. Beam magnetic core; 120. Upper magnetic core; 130. Lower magnetic core; 140. Middle magnetic core; 150. Air gap; 200. Inductor winding; 300. Isolation plate. DETAILED DESCRIPTION
[0029] The following is a description of the implementation of the present invention by means of specific embodiments. People familiar with the art can easily understand other advantages and effects of the present invention from the contents disclosed in this specification.
[0030] It should be noted that the structures, proportions, sizes, etc. illustrated in the drawings of this specification are only used to match the contents disclosed in the specification for people familiar with this technology to understand and read, and are not used to limit the limiting conditions that can be implemented in this utility model, so they have no substantial technical significance. Any modification of the structure, change of the proportional relationship or adjustment of the size, without affecting the effects that can be produced by the utility model and the purposes that can be achieved, should still fall within the scope of the technical content disclosed in this utility model. At the same time, the terms such as "upper", "lower", "left", "right", "middle" and "one" quoted in this specification are only for the convenience of description, and are not used to limit the scope of the implementation of this utility model. The change or adjustment of their relative relationship, without substantial change in the technical content, should also be regarded as the scope of the implementation of this utility model. The specific structure can be described with reference to the drawings of the patent application.
[0031] The utility model provides a high-frequency, low-loss single-phase two-in-one magnetic integrated BOOST boost inductor, please refer to Figures 1 to 3 As shown, the combined magnetic core 100 includes a crossbeam magnetic core 110, an upper jaw magnetic core 120 is provided on the left and right sides of the upper end of the crossbeam magnetic core 110, a lower jaw magnetic core 130 is provided on the left and right sides of the lower end of the crossbeam magnetic core 110, a middle column magnetic core 140 is provided between the upper jaw magnetic core 120 and the lower jaw magnetic core 130 on the left side of the crossbeam magnetic core 110, and a middle column magnetic core 140 is provided between the upper jaw magnetic core 120 and the lower jaw magnetic core 130 on the right side of the crossbeam magnetic core 110. 40, the combined magnetic core 100 is a magnetic core structure of two mirror-symmetrical "mouth" shapes; the inductor windings 200 are symmetrically wound on both sides of the combined magnetic core 100, and the inductor windings 200 are wound on the middle column magnetic core 140 on the corresponding side, and isolation plates 300 are provided between the inductor windings 200 and the upper and lower magnetic cores 120 and 130; the crossbeam magnetic core 110, the upper and lower magnetic cores 120, the lower and middle column magnetic cores 140 are all made of ferrite power material.
[0032] It should be noted that the crossbeam core 110, the upper jaw core 120, the lower jaw core 130 and the center column core 140 are all made of ferrite power material. By using a single material core, the physical and chemical properties of each component are the same, which reduces the difficulty of production and assembly and makes product quality easy to control.
[0033] Combination Figure 1 As shown, the crossbeam core 110 forms two inductors with the middle column core 140, the upper jaw core 120, the lower jaw core 130, the middle column core 140 and the inductor winding 200 on the left and right sides, and the current phase difference of the two inductors is 180°. The two-way staggered low-loss magnetic integrated inductor with a phase difference of 180° can meet the requirements of two-way operation at the same time. According to the current inflow direction and the phase difference, by adjusting the winding direction, the magnetic flux generated by the two currents can always cancel each other on the magnetic core, thereby reducing magnetic loss, increasing load inductance, and reducing system ripple; the magnetic integrated inductor can also work in one way and set the other way to sleep.
[0034] Specifically, the specific structure of the middle column magnetic core 140 is shown below. Figure 2 As shown, in this embodiment, the middle column magnetic core 140 is formed by stacking a plurality of circular magnetic blocks and then fixing them with epoxy glue, and a uniform air gap 150 is provided between each magnetic block. The thickness of the air gap 150 is 0.19 mm, so as to achieve a segmented effect of the air gap 150. The segmented air gap 150 is to prevent magnetic saturation during operation. The air gap 150 is a gap left at the intersection of the iron cores. The function of the air gap 150 is to reduce the magnetic permeability, so as to avoid magnetic saturation of the magnetic core under large AC signals or DC bias.
[0035] The ferrite power material used to make the crossbeam core 110, the upper core 120 and the lower core 130 is specifically a breathless power ferrite block core. The crossbeam core 110, the upper core 120 and the lower core 130 are integrated block cores made of breathless power ferrite material. A single material core can realize two-way inductance magnetic integration. The two magnetic circuits are isolated from each other. The two staggered magnetic integrated inductors can meet the requirements of two-way operation at the same time. According to the current inflow direction and phase difference, by adjusting the winding direction, the magnetic flux generated by the two currents can be offset on the center column at all times, thereby reducing magnetic loss, increasing load inductance, and reducing system ripple.
[0036] The inductor winding 200 is made of Litz twisted wire or Litz film-wrapped twisted wire, which can avoid eddy current loss of high-frequency products and reduce skin effect.
[0037] The crossbeam magnetic core 110 , the upper jaw magnetic core 120 , the lower jaw magnetic core 130 and the middle column magnetic core 140 are all fixedly connected by applying a single-component epoxy resin glue.
[0038] Specifically, the specific structure of the isolation plate 300 is shown below. Figure 3 As shown, in this embodiment, the outer contour of the isolation plate 300 is an elliptical runway shape, and a rectangular through hole for clamping with the beam magnetic core 110 is opened in the center of the isolation plate 300, and circular through holes for clamping with the middle column magnetic core 140 are opened on both sides of the rectangular through hole; the isolation plate 300 is an epoxy FR4 board.
[0039] The measured data of the magnetic integrated inductor in this embodiment: the test inductance value of the inductor winding 200 on the left is 110uH, and the load inductance is 108uH at 50A; the inductance value of the inductor winding 2002 on the right is 110uH, and the load inductance is 108uH at 50A; it shows that the inductor has excellent anti-saturation characteristics. The inductance value of the two windings is 220uH after the two windings are connected in series, and the inductance value of the two windings is 216uH at 50A, which is basically consistent with the sum of the inductance values of the two sides, 220uH and 216uH, respectively. The magnetic coupling of the two windings is very weak, and the magnetic circuit isolation is basically achieved.
[0040] The utility model also realizes the miniaturization and integration of magnetic components and improves the power density, thereby reducing the cost of magnetic components; it can also reduce magnetic loss and system ripple, increase load inductance, and realize multi-scenario operation.
[0041] It is obvious to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be regarded as exemplary and non-restrictive from any point of view, and the scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention. Any reference numeral in a claim should not be regarded as limiting the claim to which it relates.
Claims
1. A high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor, characterized in that: It includes a combined magnetic core, wherein the combined magnetic core is provided with a crossbeam magnetic core, an upper jaw magnetic core is provided on the left and right sides of the upper end of the crossbeam magnetic core, a lower jaw magnetic core is provided on the left and right sides of the lower end of the crossbeam magnetic core, a middle column magnetic core is provided between the upper jaw magnetic core and the lower jaw magnetic core on the left side of the crossbeam magnetic core, and a middle column magnetic core is also provided between the upper jaw magnetic core and the lower jaw magnetic core on the right side of the crossbeam magnetic core, and the combined magnetic core presents two mirror-symmetrical "mouth"-shaped magnetic core structures; Inductance windings are symmetrically wound on both sides of the combined magnetic core, and the inductance windings are wound on the middle column magnetic cores on the corresponding sides, and isolation plates are provided between the inductance windings and the upper magnetic core and the lower magnetic core; The crossbeam magnetic core, the upper jaw magnetic core, the lower jaw magnetic core and the middle column magnetic core are all made of ferrite power material.
2. According to claim 1, a high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor is characterized in that: The crossbeam magnetic core forms two inductance paths with the middle column magnetic core, the upper jaw magnetic core, the lower jaw magnetic core, the middle column magnetic core and the inductor winding on the left and right sides, and the current phase difference between the two inductance paths is 180°.
3. According to claim 1, a high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor is characterized in that: The central column magnetic core is formed by stacking a plurality of circular magnetic blocks and then bonding and fixing them with epoxy adhesive, and a uniform air gap is provided between each magnetic block.
4. The high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor according to claim 3, characterized in that: The air gap thickness is 0.13-0.5 mm.
5. The high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor according to claim 1, characterized in that: The ferrite power material used to make the crossbeam core, the upper jaw core and the lower jaw core is specifically a breathless power ferrite block core, and the crossbeam core, the upper jaw core and the lower jaw core are integrated block cores made of breathless power ferrite material.
6. The high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor according to claim 1, characterized in that: The inductor winding is made of Litz stranded wire or Litz film-wrapped stranded wire.
7. The high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor according to claim 1, characterized in that: The crossbeam magnetic core, the upper jaw magnetic core, the lower jaw magnetic core and the middle column magnetic core are all fixedly connected by applying epoxy resin single-component glue.
8. The high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor according to claim 1, characterized in that: The outer contour of the isolation plate is an elliptical racetrack shape. A rectangular through hole for clamping with the crossbeam magnetic core is opened in the center of the isolation plate, and circular through holes for clamping with the middle column magnetic core are opened on both sides of the rectangular through hole.
9. The high-frequency, low-loss, single-phase two-in-one magnetic integrated BOOST boost inductor according to claim 8, characterized in that: The isolation board is an epoxy FR4 board.