Composite Magnetic Core Inductor for DC Superposition
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Solution Overview
Problem
Conventional inductors face challenges in reducing volume and manufacturing costs due to the need for air gaps in magnetic cores, which complicates processing and increases the volume of the inductor, making it difficult to achieve slim and light designs while maintaining performance, especially in applications like solar power and automotive industries.
Innovation Solution
The design incorporates three magnetic cores where the first and second cores are made of the same soft magnetic powder material, and the third core is made of a different soft magnetic powder material with higher saturation magnetic flux density and lower core loss, allowing for enhanced DC superposition characteristics and reduced core loss, thereby minimizing copper wire usage and preventing characteristic degradation due to temperature increases.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If air gaps are formed in magnetic cores through separate cutting processes, then inductor performance is improved, but manufacturing costs increase and device volume increases
Solution Approach 1:
The patent merges the air gap formation process with the magnetic core manufacturing process itself. The air gaps are formed as integral parts of the magnetic core structure during molding, eliminating the need for separate cutting processes. This integration reduces manufacturing steps and costs while maintaining the required air gaps for inductor performance.
Solution Approach 2:
The air gaps are pre-formed during the magnetic core manufacturing process before the winding process begins. By incorporating air gap formation as a preliminary step in the core fabrication, the patent eliminates subsequent cutting operations and reduces overall manufacturing complexity and cost.
2Reliability
If air gaps are formed in magnetic cores through separate cutting processes, then inductor performance is improved, but device volume increases
Solution Approach 1:
The patent merges the air gap formation with the core manufacturing process, allowing air gaps to be created as integral features of the magnetic core structure. This integration enables more efficient space utilization and reduces the overall inductor volume compared to adding separate air gap components.
3Ease of manufacture
If conventional magnetic core structures are used, then manufacturing is simplified, but DC superposition characteristics degrade and core loss increases
Solution Approach 1:
The patent applies different material properties to different parts of the magnetic core structure. Specifically, it uses materials with different saturation magnetic flux densities in different core regions, optimizing local magnetic characteristics to improve overall DC superposition performance while maintaining manufacturing feasibility.
Solution Approach 2:
The patent employs composite magnetic core structures made from multiple materials with different soft magnetic powder compositions. This composite approach allows optimization of both DC superposition characteristics and core loss by selecting materials with complementary properties for different portions of the core.
4Ease of manufacture
If conventional magnetic core structures are used, then manufacturing is simplified, but core loss increases due to temperature degradation
Solution Approach 1:
The patent applies different material properties to different parts of the magnetic core structure. Specifically, it uses materials with different saturation magnetic flux densities in different core regions, optimizing local magnetic characteristics to improve overall DC superposition performance while maintaining manufacturing feasibility.
Solution Approach 2:
The patent employs composite magnetic core structures made from multiple materials with different soft magnetic powder compositions. This composite approach allows optimization of both DC superposition characteristics and core loss by selecting materials with complementary properties for different portions of the core.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enables an inductor with improved efficiency and reduced volume, allowing for enhanced DC superposition characteristics and minimized core loss, while also simplifying the structure and reducing manufacturing costs by optimizing core material selection.
Implementation Method 1
the third magnetic core is formed of a soft magnetic powder different from the first magnetic core and the second magnetic core, wherein the soft magnetic powder of the third magnetic core has a greater saturation magnetic flux density than those of the first magnetic core and the second magnetic core
Data Source
AI summary
An inductor includes a first magnetic core around which a first coil is wound; a second magnetic core disposed to face the first magnetic core and having a second coil wound therearound; and a third magnetic core disposed between the first magnetic core and the second magnetic core, wherein the first magnetic core and the second magnetic core are formed of the same material having a soft magnetic powder, and the third magnetic core is formed of a material having a soft magnetic powder different from the first magnetic core and the second magnetic core.