Coupled Inductor With Perpendicular Windings For Compact Core Utilization
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Solution Overview
Problem
Conventional coupled inductors are inefficient in utilizing core material volume, leading to larger sizes due to suboptimal winding arrangements.
Innovation Solution
The coupled inductor design features windings with larger side faces arranged perpendicular to the core's lower side, utilizing the core's volume more effectively, and a split core with precisely controlled parts for compact assembly, including grooves for winding placement and electrical isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional winding arrangements are used, then the inductor can be manufactured with standard techniques, but the core material volume is not efficiently utilized leading to larger device size
Solution Approach 1:
The core is divided into two separate parts (first core part and second core part) that can be manufactured independently and then assembled together. This segmentation allows for precise control of the core geometry and winding placement, enabling efficient core material utilization while maintaining manufacturability through standard assembly techniques.
Solution Approach 2:
The windings are arranged in an intermediate section that extends through a through-hole in the core, with larger side faces oriented perpendicular to the core's lower side. This three-dimensional winding configuration optimizes the utilization of core material volume by utilizing the vertical dimension and lateral space more effectively than conventional planar arrangements.
2Ease of manufacture
If the core is split into multiple parts for easier manufacturing, then assembly becomes more complex, but manufacturing ease is improved
Solution Approach 1:
The core is divided into two parts that can be manufactured using standard techniques with precise dimensional control. The segmentation enables independent optimization of each core part and simplifies the winding assembly process, as windings can be positioned in the intermediate section before final assembly. The parts are connected through a parting plane with precise spacing control.
Solution Approach 2:
A distance element is introduced between the first core part and second core part to precisely control the spacing at the parting plane. This intermediary component ensures accurate alignment and spacing during assembly, reducing assembly complexity by providing a built-in positioning mechanism rather than requiring complex adjustment procedures.
3Reliability
If winding size is increased to improve magnetic properties, then the inductor occupies more space, but electric and magnetic properties are improved
Solution Approach 1:
The windings are configured as flat stripes with larger side faces oriented perpendicular to the core's lower side, utilizing the vertical dimension and lateral space more effectively. This three-dimensional arrangement increases the effective winding area and magnetic coupling without proportionally increasing the overall inductor volume, achieving better magnetic properties in a compact form factor.
Solution Approach 2:
The intermediate section of the windings is positioned to extend through a through-hole in the core before final assembly. This preliminary placement ensures optimal positioning and maximizes the utilization of core material volume, allowing the windings to be tightly coupled with the core material and achieve high magnetic efficiency in a compact configuration.
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 design reduces the size of the coupled inductor to less than half that of conventional models while maintaining improved electric and magnetic properties.
Implementation Method 1
a coupled inductor having a core and two windings
Data Source
Figure 1~2
Figure 3~4
AI summary
The invention refers to a coupled inductor having a core and two windings, wherein the first winding has a first and a second terminal end and wherein the second winding has a third and a fourth terminal end, wherein the first to fourth terminal ends are arranged on a lower side of the core, wherein each winding has an intermediate section extending through a through-hole in the core, wherein the two windings are designed at least in the intermediate section as flat stripes each having first and second side faces with a large width and third and fourth side faces having a small width compared to the width of the first and second side faces, wherein the first side faces of both windings are arranged in the intermediate section perpendicular to the lower side of the core and wherein the two first side faces of the windings in the intermediate section face each other and/or abut each other in the intermediate section.