Inductor Structure with Segmented Core and Opposing Windings
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Solution Overview
Problem
Inductors face issues with near field radiation due to leakage magnetic flux, which is not effectively managed in conventional designs, leading to electromagnetic interference (EMI) challenges in power electronics and other applications.
Innovation Solution
The design incorporates a magnetic core with air gaps between its legs and windings configured to generate magnetic fluxes in opposite directions, reducing leakage flux through the strategic placement of windings and air gaps, which minimizes near field radiation by canceling out leakage magnetic fluxes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If a conventional inductor design with a magnetic core and winding is used, then the inductor can store and transfer electromagnetic energy, but leakage magnetic flux is generated causing near field radiation and electromagnetic interference
Solution Approach 1:
The magnetic core is segmented into multiple legs (first leg, second leg, third leg) with windings distributed across different legs. This segmentation allows the magnetic flux paths to be divided and redirected through the air gaps, reducing concentrated leakage flux and near field radiation from any single winding location.
Solution Approach 2:
Air gaps are introduced as intermediary elements between the magnetic core legs. These air gaps serve as magnetic flux pathways that redirect and contain the magnetic flux within the core structure, preventing leakage flux from escaping into the surrounding medium and reducing near field radiation.
2Reliability
If the magnetic core has high permeability to confine magnetic flux, then energy storage and transfer is improved, but coupling between winding and surrounding medium still generates leakage flux
Solution Approach 1:
The magnetic core is divided into multiple legs with windings distributed across them. This segmentation creates multiple magnetic flux paths through the high permeability core material, ensuring that the magnetic flux remains confined within the core structure while the distributed winding arrangement prevents concentrated leakage flux generation.
Solution Approach 2:
Air gaps are positioned between magnetic core legs to act as intermediaries that guide and contain magnetic flux. These air gaps provide controlled magnetic flux pathways that work synergistically with the high permeability core material to maintain flux confinement while preventing leakage into the surrounding medium.
3Device complexity
If windings are placed around a single magnetic core leg, then the inductor structure is simple, but near field radiation is significant due to concentrated leakage flux
Solution Approach 1:
The inductor structure is segmented into multiple legs with windings distributed across different legs. This segmentation distributes the magnetic flux generation across multiple locations, reducing concentrated leakage flux and near field radiation while maintaining a relatively simple overall structure that builds upon conventional inductor designs.
Solution Approach 2:
Multiple windings on different legs are combined to create a distributed magnetic flux pattern. The magnetic fluxes from different legs interact and cancel each other's leakage components, reducing near field radiation while the combined structure maintains simplicity by using standard magnetic core and winding components.
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 significantly reduces near field radiation, enhancing the inductor's ability to meet tight EMI requirements by effectively confining magnetic flux within the core and minimizing external leakage, thereby improving performance in power converters and other applications.
Implementation Method 1
the first winding and the second winding are configured to flow a current and generate a first magnetic flux in the first leg and a second magnetic flux in the second leg
Implementation Method 2
the magnetic core usually has a relatively high permeability in comparison with the surrounding medium (e.g., air). As a result, the magnetic flux is confined with the magnetic core, which is a closed flux path
Data Source
AI summary
A device comprises a magnetic core comprising a first leg and a second leg formed by a first magnetic component and a second magnetic component, wherein a first gap and a second gap are placed between the first magnetic component and the second magnetic component and are in the first leg and the second leg, respectively, a first winding wound around the first leg in a counter-clockwise direction and a second winding wound around the second leg in a clockwise direction.