Integrated Coupled Inductor Structure With Adjustable Magnetic Coupling
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Solution Overview
Problem
Coupled inductor devices are prone to short circuits during winding formation and have an inflexible coupling coefficient, limiting energy storage capacity and anti-saturation performance.
Innovation Solution
An integrally formed coupled inductive device with insulative magnetic cores and non-magnetic insulative layers between windings, allowing adjustable coupling coefficients and preventing short circuits through controlled thickness of the insulative layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coupled inductor device is composed of two magnetic cores with primary and secondary windings, then the device can provide magnetic coupling between phases, but the device is prone to causing short circuits during the forming process of windings and the coupling coefficient is not easily adjustable
Solution Approach 1:
The patent merges two separate magnetic cores into a single integrated magnetic core structure with multiple grooves. The primary and secondary windings are both wound on the same magnetic core, eliminating the need for separate magnetic cores and reducing structural complexity while preventing short circuits through the integrated design with insulative layers between windings
Solution Approach 2:
The patent introduces a non-magnetic insulative layer as an intermediary between the primary winding and secondary winding. This insulative layer prevents direct contact and potential short circuits between windings, while still allowing magnetic flux to pass through, thus maintaining the coupling function while ensuring electrical isolation
2Adaptability or versatility
If traditional coupled inductor uses fixed magnetic core structure, then the device can provide stable magnetic coupling, but the coupling coefficient between primary and secondary windings is not easily adjustable
Solution Approach 1:
The patent enables adjustment of the coupling coefficient by changing the thickness of the non-magnetic insulative layer between windings. By varying this parameter (insulative layer thickness), the magnetic coupling between primary and secondary windings can be controlled, allowing flexible adjustment of the coupling coefficient without redesigning the entire magnetic core structure
Solution Approach 2:
The patent transforms the static, fixed coupling coefficient of traditional coupled inductors into a dynamic, adjustable parameter. The insulative layer thickness can be modified during manufacturing or design to achieve different coupling coefficients, making the device adaptable to various application requirements while maintaining ease of manufacture through a standardized modular approach
3Reliability
If coupled inductor device uses conventional winding formation process, then the device can be manufactured, but the device is prone to causing short circuits during the forming process of primary and secondary windings
Solution Approach 1:
The patent applies the non-magnetic insulative layer to the magnetic core before winding the primary and secondary windings. This preliminary insulation preparation ensures that electrical isolation is established before the winding formation process begins, preventing short circuits during manufacturing while maintaining reasonable manufacturing precision through a straightforward coating or layering process
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
Enhances energy storage capacity and anti-saturation performance by adjusting the coupling coefficient and preventing short circuits.
Implementation Method 1
the coupling coefficient between two windings in the two adjacent grooves is related to the thickness of the non-magnetic insulative layer disposed between the two windings
Implementation Method 2
An accommodating hole extends in a second direction and is located between two adjacent grooves, and two adjacent grooves disposed in the first direction are connected through an accommodating hole. The second direction intersects the first direction.
Data Source
AI summary
Provided are a coupled inductive device and a method for preparing an integrally formed coupled inductive device. The coupled inductive device includes an insulative magnetic core and at least two windings, where at least two grooves are disposed in the insulative magnetic core at intervals along a first direction; and the at least two windings are located in the at least two grooves in one-to-one correspondence. The insulative magnetic core further includes at least one accommodating hole and a non-magnetic insulative layer located in the accommodating hole, where an accommodating hole extends in a second direction and is located between two adjacent grooves, two adjacent grooves disposed in the first direction are connected through an accommodating hole, and the coupling coefficient between two windings in the two adjacent grooves is related to the thickness of the non-magnetic insulative layer disposed between the two windings in a third direction.