Inductive magnetic core, interleaved integrated inductor and power conversion device

Abstract

The application relates to the field of inductors and power conversion devices, in particular to an inductor magnetic core, an interleaved integrated inductor and a power conversion device, which comprises an inductor magnetic core, the magnetic core comprising a first side column, a second side column, a middle column, an upper magnetic block and a lower magnetic block, the first side column, the second side column, the upper magnetic block and the lower magnetic block being magnetic powder core materials, the middle column being made of ferrite material, the upper ends of the first side column and the second side column being connected through the upper magnetic block and the lower magnetic block respectively, the middle column being located between the first side column and the second side column and each column being independently arranged; the interleaved integrated inductor adopts the inductor magnetic core, the first side column and the second side column being wound with flat wire coils with opposite winding directions; and the power conversion device adopts the interleaved integrated inductor. The application achieves the effects of optimizing the structure of the inductor magnetic core, improving the performance of the interleaved integrated inductor and further improving the overall performance of the power conversion device.

Description

Technical Field

[0001] This application relates to the field of inductors and power conversion, and more particularly to an interleaved integrated inductor and an inductor core including the inductor, an interleaved integrated inductor and a power conversion device. Background Technology

[0002] In the field of power electronics, power conversion devices play a crucial role as core components. They convert one type of electrical energy into another to adapt to different application scenarios and needs, and are widely used in various electronic devices, industrial production, and power systems. With the continuous development of electronic technology, the performance and efficiency requirements of power conversion devices are also increasing. As a key component in power conversion devices, the performance of inductors directly affects the overall performance of the device. Good inductor performance helps improve the stability, efficiency, and accuracy of power conversion, thereby promoting the efficient operation of electronic devices and power systems and meeting the ever-increasing electricity demand.

[0003] Currently, in traditional inductor design, an air gap is typically created in the magnetic core to meet certain electrical performance requirements. This is a common technique that adjusts the magnetic reluctance of the magnetic circuit to achieve the desired inductance value. However, when the air gap increases the magnetic reluctance, the core size or the number of coil turns is often increased to compensate for this change. Increasing the core size provides more space in the magnetic circuit, while increasing the number of coil turns strengthens the magnetic field, thus maintaining the inductor's performance.

[0004] However, these existing traditional inductor design methods have significant drawbacks. Creating an air gap in the magnetic core generates substantial leakage flux and increases eddy current losses in the coil, reducing inductor efficiency. Furthermore, increasing the core size or the number of coil turns to compensate for the increased magnetic reluctance caused by the air gap indirectly leads to a larger inductor volume, hindering the miniaturization and integration of power conversion devices. Utility Model Content

[0005] To address the aforementioned problems, this application provides an inductor core, an interleaved integrated inductor, and a power conversion device.

[0006] On the one hand, this application provides an inductor core, which adopts the following technical solution: An inductor core includes a first side post, a second side post, a middle post, an upper magnetic block, and a lower magnetic block; the first side post, the second side post, the upper magnetic block, and the lower magnetic block are all made of low permeability materials; the middle post is made of a high permeability material. The central column is located between the first and second side columns. The upper ends of the first and second side columns are connected to the central column via upper magnetic blocks. The lower ends of the first and second side columns are connected to the central column via lower magnetic blocks.

[0007] By adopting the above technical solution, the middle column uses a high permeability material with an initial permeability of over 3000, such as ferrite, while the side columns use a low permeability material with an initial permeability of less than 100, such as powder core. This allows most of the magnetic flux to pass through the middle column, achieving a low coupling between the first and second side column inductances. On the other hand, the windings are positively coupled, and the magnetic flux through the middle column cancels out. Furthermore, the unique distributed air gap characteristic of the iron powder core material eliminates the need for an additional air gap, resulting in a more uniform magnetic loss distribution.

[0008] Preferably, the first side post, the second side post, and the middle post are set independently.

[0009] By adopting the above technical solution, the first side post, the second side post, and the middle post can be processed independently and then assembled. This structural design allows the coils to be pre-wound independently and then fitted onto their respective side posts, thereby simplifying the coil winding process and improving processing convenience and assembly efficiency.

[0010] Secondly, this application provides an interleaved integrated inductor, employing the following technical solution: An interleaved integrated inductor includes the inductor core described above, wherein coils are wound on both the first and second side posts, and the winding directions are opposite.

[0011] By adopting the above technical solution, the windings corresponding to the first and second side columns are positively coupled. Therefore, the power frequency magnetic flux in the middle column cancels each other out, while the high-frequency magnetic flux in the middle column is superimposed, effectively reducing the magnetic flux density in the middle column and thus reducing the volume. In addition, the positive coupling of magnetic flux, the cancellation of power frequency flux, and the superposition of high-frequency flux are suitable for high-power applications.

[0012] Preferably, the coil is made of flat wire.

[0013] By adopting the above technical solution, there is no need to use Litz wire to reduce copper loss; flat wire can be used directly, which has the advantage of lower cost.

[0014] Thirdly, this application provides a power conversion device, which adopts the following technical solution: A power conversion device employs the aforementioned interleaved integrated inductor.

[0015] By adopting the above technical solutions, the efficiency of power conversion devices can be effectively improved, and their size can be reduced, thus saving costs.

[0016] In summary, this application includes at least one of the following beneficial technical effects: 1. The middle column uses ferrite with high permeability, while the side columns use magnetic powder core with lower permeability, so that most of the magnetic flux passes through the middle column, achieving low coupling between the first and second side column inductances; and the use of iron powder core material eliminates the need for additional air gaps, resulting in more uniform magnetic loss distribution. 2. The first side post, the second side post, and the central post are set independently and can be processed separately and then spliced ​​together, which simplifies the processing and helps to reduce the volume; 3. The windings corresponding to the first and second side columns are positively coupled, so the power frequency magnetic flux in the middle column cancels each other out, and the high frequency magnetic flux in the middle column is superimposed, which effectively reduces the magnetic flux density in the middle column and helps to reduce the volume. 4. The coil of the inductor in this application uses flat wire, eliminating the need for Litz wire to reduce copper losses, thus reducing costs. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of the interleaved integrated inductor in the embodiments of this application; Figure 2 This is an exploded view of the structure of the interleaved integrated inductor in the embodiments of this application; Figure 3 This is a circuit diagram of the power conversion device in the embodiments of this application; Figure 4 This is a schematic diagram of the magnetic flux of the interleaved integrated inductor over a period of time in an embodiment of this application.

[0018] The following are labels in the attached diagram: 1. First side post; 2. Second side post; 3. Middle post; 4. Upper magnetic block; 5. Lower magnetic block; 6. Coil. Detailed Implementation

[0019] The following is in conjunction with the appendix Figure 1 - Figure 4 This application will be described in further detail.

[0020] This application provides an inductor core, an interleaved integrated inductor, and a power conversion device.

[0021] Reference Figure 1 and Figure 2 The inductor core includes a first side post 1, a second side post 2, a middle post 3, an upper magnetic block 4, and a lower magnetic block 5. The first side post 1, the second side post 2, the upper magnetic block 4, and the lower magnetic block 5 are all made of low permeability materials, such as powder cores. The middle post 3 is made of high permeability materials, such as ferrite. The middle post 3 is located between the first side post 1 and the second side post 2. The upper ends of the first side post 1 and the second side post 2 are both connected to the middle post 3 through the upper magnetic block 4. The lower ends of the first side post 1 and the second side post 2 are both connected through the lower magnetic block 5. The specific connection method can be adhesive bonding.

[0022] In this application, low permeability materials specifically refer to those with an initial permeability of less than 100; while high permeability materials specifically refer to those with an initial permeability of more than 3000.

[0023] The interleaved integrated inductor uses the aforementioned inductor core, and coils 6 are wound on the first and second side posts 1 to form the inductance. Since the middle post 3 uses high-permeability ferrite and the side posts use lower-permeability magnetic powder cores, most of the magnetic flux passes through the middle post 3, achieving low coupling between the inductors of the first and second side posts 1 and 2. The windings are positively coupled, and the magnetic flux of the middle post cancels out. At the same time, the unique distributed air gap material characteristics of the magnetic powder core eliminate the need for an additional air gap, making the magnetic loss distribution more uniform and helping to improve efficiency.

[0024] Reference Figure 3 The power conversion device uses the interleaved integrated inductors mentioned above, which helps to reduce size and cost and improve power efficiency.

[0025] Specifically, the magnetic powder core material used for the first side post 1, the second side post 2, the upper magnetic block 4, and the lower magnetic block 5 is preferably iron-silicon-aluminum powder core, which has the advantages of low loss and high cost performance. The first side post 1, the second side post 2, and the middle post 3 are set separately and independently, and are connected and fixed to each other through assembly.

[0026] Reference Figure 4 The windings on the first side post 1 and the second side post 2 are positively coupled, so the power frequency magnetic flux at the middle post cancels each other out, while the high-frequency magnetic flux at the middle post 3 is superimposed. For details, refer to... Figure 4 This figure illustrates the magnetic flux of an interleaved integrated inductor over a period of time. The horizontal axis represents time, and the vertical axis represents magnetic flux. Figure 4 In the middle section, the power frequency portion remains approximately constant, while the high-frequency portions are interleaved. This effectively reduces the magnetic flux density of the central column 3, which is beneficial for reducing volume. Furthermore, because the central column uses a high-permeability ferrite material, it has lower losses compared to all-powder core materials, thus improving efficiency.

[0027] Furthermore, coil 6 uses flat wire, eliminating the need for Litz wire to reduce copper loss, resulting in a lower cost advantage.

[0028] The implementation principle of this embodiment is as follows: By using a combination of different materials, this embodiment utilizes the high permeability of ferrite and the distributed air gap characteristics of the magnetic powder core to achieve low coupling and uniform magnetic loss distribution in the inductor core. Compared with traditional inductor cores, no additional air gap is required, reducing coil losses. It also helps to reduce the size of the inductor, improving the performance and efficiency of the power conversion device, and meeting the development needs of miniaturization and integration of electronic devices.

[0029] The above are all preferred embodiments of this application and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. An inductor core, characterized in that, It includes a first side post (1), a second side post (2), a middle post (3), an upper magnetic block (4), and a lower magnetic block (5); the first side post (1), the second side post (2), the upper magnetic block (4), and the lower magnetic block (5) are all made of low permeability materials; the middle post (3) is made of high permeability material; The central column (3) is located between the first side column (1) and the second side column (2); the upper ends of the first side column (1) and the second side column (2) are connected to the central column (3) through the upper magnetic block (4); the lower ends of the first side column (1) and the second side column (2) are connected to the central column through the lower magnetic block (5).

2. The inductor core according to claim 1, characterized in that, The first side post (1), the second side post (2), and the middle post (3) are set independently.

3. An interleaved integrated inductor, characterized in that, The inductor core includes any one of claims 1-2, wherein coils (6) are wound on both the first side post (1) and the second side post (2), and the winding directions are opposite.

4. The interleaved integrated inductor according to claim 3, characterized in that, The coil (6) is made of flat wire.

5. A power conversion device, characterized in that, The interleaved integrated inductor described in claim 3 is used.

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