Coupled Inductor Air-Gap Tuning for Adjustable Leakage Inductance
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Solution Overview
Problem
Conventional inductor structures in voltage converters suffer from limited directional flexibility and inflexible electromagnetic circuit selection, leading to energy loss and potential damage due to magnetic core saturation.
Innovation Solution
A coupled inductor with adjustable leakage inductance is designed, comprising a first and second magnetic element with magnetic core columns and coil assemblies, allowing for adjustable gaps to control magnetic resistance and permeability, thereby adjusting leakage inductance and electromagnetic circuit directionality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional inductor structures are used, then the structure is simple and easy to manufacture, but the electromagnetic circuit directionality is limited and the selection is inflexible
Solution Approach 1:
The inductor is divided into multiple magnetic core columns (first, second, third, and fourth magnetic core columns) with distinct winding directions. Each magnetic core column can be independently configured to achieve different electromagnetic circuit configurations, enabling flexible directionality selection while maintaining a modular structure that is relatively easy to manufacture.
Solution Approach 2:
The patent introduces adjustable air gaps between magnetic core columns, allowing the magnetic coupling between windings to be dynamically adjusted. By changing the gap distances, the leakage inductance can be tuned to achieve different electromagnetic circuit characteristics, providing adaptability without requiring complete structural redesign.
2Reliability
If magnetic core saturation occurs, then the voltage converter loses energy exchange function, but increasing magnetic core size to prevent saturation increases device volume
Solution Approach 1:
The magnetic core is segmented into multiple columns with different winding directions, allowing each segment to handle specific flux paths. This segmentation distributes the magnetic flux more efficiently, preventing any single core region from saturating while maintaining a compact overall structure.
Solution Approach 2:
Different magnetic core columns are assigned different winding directions and local magnetic path characteristics. This local differentiation optimizes the magnetic flux distribution across the core, ensuring that each region operates within its optimal range and preventing saturation without requiring uniform increases in core size.
3Adaptability or versatility
If fixed leakage inductance is used, then the inductor structure is simple, but the electromagnetic circuit selection is inflexible and cannot meet practical requirements
Solution Approach 1:
The patent implements adjustable leakage inductance by introducing variable air gaps between magnetic core columns. The gap distances can be modified to change the magnetic coupling between windings, thereby dynamically adjusting the leakage inductance to meet different circuit requirements without complicating the basic structure.
Solution Approach 2:
The leakage inductance is adjusted by changing the physical parameter of air gap distance between magnetic core columns. This parameter change allows flexible control of electromagnetic characteristics while maintaining a relatively simple structural configuration that can be adapted to various practical requirements.
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
The adjustable leakage inductance improves the electromagnetic characteristics of voltage converters, increases power output, reduces internal energy loss, and allows for flexible electromagnetic circuit configurations to meet practical requirements.
Implementation Method 1
Due to electromagnetic induction, the current change in one wire causes the electromotive force to pass through one end of another wire. An interaction between the two conductors is called mutual inductance coupling, or magnetic coupling.
Implementation Method 2
An interaction between the two conductors is called mutual inductance coupling, or magnetic coupling. The at least two second magnetic core columns are respectively coupled with the at least two first magnetic core columns to form at least two magnetic core column bodies.
Implementation Method 3
A coupling position between the second magnetic core column and a corresponding on of the first magnetic core column to which the second magnetic core column is coupled has a gap.
Data Source
AI summary
A coupled inductor with adjustable leakage inductance is provided. The coupled inductor includes a first magnetic element, a second magnetic element, and two coil assemblies. The first magnetic element includes a first magnetic plate and at least two first magnetic core columns, which are disposed on the first magnetic plate and spaced apart along an arrangement direction. The second magnetic element is coupled to the first magnetic element. The second magnetic element includes a second magnetic plate and at least two second magnetic core columns, which are disposed on the second magnetic plate and spaced apart along the arrangement direction. The second magnetic core columns are respectively coupled to the first magnetic core columns to form magnetic core column bodies. The coil assemblies have a same quantity as that of the magnetic core column bodies, and the coil assemblies are respectively sleeved around the magnetic core columns.