DC-DC Converter Inductor With Crack-Free Laminated Magnetic Core
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing DC-DC converters face challenges in improving characteristics such as loss, inductance, and DC superimposition while maintaining a reduced size, particularly due to the use of magnetic cores with laminated magnetic thin strips that are prone to cracking.
Innovation Solution
The use of inductors with crack-free magnetic thin strips and coil conductors in a laminated structure for the DC-DC converter, which includes a specific circuit configuration with capacitor voltage dividing, reduces losses and allows for a smaller device size by suppressing inductor coupling and ripple occurrence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic thin strips are laminated to form a magnetic core, then the inductance characteristics are improved, but cracks occur in the magnetic thin strips causing deterioration of performance
Solution Approach 1:
The patent uses amorphous alloy material which has inherent crack resistance properties, combining the high permeability needed for good inductance characteristics with the structural integrity to prevent cracking. The amorphous structure provides both magnetic performance and mechanical strength.
Solution Approach 2:
The patent specifies controlling the thickness of magnetic thin strips within a specific range (3 μm to 10 μm) to balance magnetic performance and crack resistance. By optimizing this critical parameter, the design achieves both good inductance characteristics and resistance to cracking.
2Volume of moving object
If the DC-DC converter size is reduced, then compactness is improved, but loss increases due to inductor coupling and ripple
Solution Approach 1:
The patent divides the inductor into multiple magnetic thin strips laminated together, which segments the magnetic path and reduces eddy current losses. This segmentation approach allows for compact design while maintaining low loss characteristics by minimizing coupling effects between adjacent windings.
Solution Approach 2:
The patent introduces a resin layer as an intermediary between magnetic thin strips to provide electrical insulation and mechanical bonding. This intermediary prevents direct contact between adjacent strips, reducing eddy current paths and ripple while maintaining the compact laminated structure.
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 enhances the DC-DC converter's performance by reducing losses and size while maintaining or improving inductance values and DC superposition saturation current, thereby optimizing the converter's efficiency and compactness.
Implementation Method 1
The magnetic body has a laminated structure with a plurality of magnetic thin strips laminated
Implementation Method 2
a first coil conductor, a magnetic body adjacent to the first coil conductor
Implementation Method 3
a first capacitor and a first inductor connected in series in this order
Data Source
AI summary
A DC-DC converter of a power supply circuit can improve characteristics in view of loss reduction by using, as an inductor, a coil conductor of an inductance element including, as a core, a magnetic block configured with crack free magnetic thin strips.