Integrated Coupling Inductor Gaps for Saturation and Loss Control
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Solution Overview
Problem
Conventional inductor structures in electronic devices face limitations due to magnetic saturation, leading to reduced inductance and increased energy loss, which can result in damage to voltage converters.
Innovation Solution
The integrated coupling inductor features a magnetic core frame with a spatial relationship that allows for controllable leakage inductance and reduced loss, achieved through the use of magnetic core columns and side magnetic cores that create gaps within the magnetic circuit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the magnetic flux of the internal inductor reaches the maximum value, then the magnetic core is in a state of magnetic saturation, but the voltage converter loses the function of energy exchange and energy is lost in the internal damping of the coil
Solution Approach 1:
The inductor is divided into multiple independent windings (first winding, second winding, third winding, fourth winding) with separate magnetic core columns. This segmentation allows each winding to operate independently within its magnetic saturation limits, preventing overall saturation and reducing energy loss in the magnetic core.
Solution Approach 2:
The patent introduces a spatial dimension by arranging windings and magnetic core columns in three-dimensional space with specific geometric relationships. The magnetic core columns are positioned at different locations (first, second, third, fourth columns) and windings are wound in different directions, creating a multi-dimensional magnetic circuit that increases power handling capability before saturation occurs.
2Adaptability or versatility
If the directionality of an electromagnetic circuit is limited due to the structural design of the inductor, then the selection of the electromagnetic circuit is inflexible, but the inductance used in electronic devices cannot be improved
Solution Approach 1:
The inductor structure with multiple windings and magnetic core columns can serve multiple electromagnetic circuit functions. By selectively connecting different windings in series or parallel configurations, the inductor can provide different inductance values and magnetic coupling characteristics, making it adaptable to various electromagnetic circuit requirements while maintaining high inductance performance.
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 enhances the saturation current and power handling capabilities of the inductor, while reducing internal losses and allowing for flexible electromagnetic circuit configurations.
Implementation Method 1
when the magnetic flux of the internal inductor reaches the maximum value, the magnetic core of the inductor is in a state of magnetic saturation
Implementation Method 2
The gap can affect the magnetic resistance of the coupling inductor, the effective magnetic permeability of the magnetic core, the current, the leakage inductance and other electromagnetic factors
Implementation Method 3
the integrated coupling inductor can have one or more gaps. The gap can affect the magnetic resistance of the coupling inductor, the effective magnetic permeability of the magnetic core, the current, the leakage inductance and other electromagnetic factors
Data Source
AI summary
An integrated coupling inductor includes a magnetic core frame, a magnetic core, two magnetic core columns, and two coil assemblies. The magnetic core is disposed on the magnetic core frame. In a first direction, a first space and a second space are defined by the magnetic core and the two inner wall surfaces of the magnetic core frame. In a second direction, a third space and a fourth space is defined by the magnetic core and two inner wall surfaces of the magnetic core frame. The two magnetic core columns are respectively disposed in the first space and the second space. One end of each of the magnetic core columns is connected to the magnetic core, and another end extends toward the inner wall surface of the magnetic core frame. The two coil assemblies are respectively sleeved around the two magnetic core columns.