Integrated Inductor Layout for Low Core Loss and Compact Size

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Solution Overview

Problem

Existing integrated inductors experience significant magnetic core loss at high frequencies due to overlapping magnetic fluxes, and their volume cannot be effectively reduced.

Innovation Solution

The integrated inductor design features parallel winding columns with air gaps, a common column connecting the cover plates, and windings wound in the same direction for line frequency currents, with a 180° phase difference for high-frequency currents, resulting in a weak coupling coefficient to minimize magnetic flux overlap.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If windings are wound in opposite directions on parallel columns to reduce magnetic flux overlap, then volume is reduced, but magnetic core loss increases at high frequency

Engineering Contradiction:

Improveinductor volumeVSAvoidmagnetic core loss

Core Design Contradiction:

Volume of stationary objectVSLoss of energy

Solution Approach 1:

The patent inverts the conventional winding approach by winding both windings in the same direction rather than opposite directions. This inversion changes the magnetic flux interaction from overlapping (harmful for volume) to opposing (beneficial for reducing core loss at high frequency), resolving the technical contradiction between volume reduction and loss minimization.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent changes the winding direction parameter from the conventional opposite directions to the same direction, while simultaneously introducing a 180° phase difference in the high-frequency current components. This parameter change transforms the magnetic flux interaction pattern to achieve both volume reduction and reduced core loss.

Inventive Principle:

Principle #35Parameter changes

2Volume of stationary object

If common column size is minimized through reverse overlap effect, then inductor volume is reduced, but thickness of cover plates cannot be reduced

Engineering Contradiction:

Improvecommon column sizeVSAvoidcover plate thickness reduction capability

Core Design Contradiction:

Volume of stationary objectVSAdaptability or versatility

Solution Approach 1:

The patent inverts the magnetic flux interaction approach to achieve opposing fluxes throughout the entire magnetic core structure, not just on the common column. This enables reduction of cover plate thicknesses while maintaining structural integrity and magnetic performance, overcoming the limitation of the conventional reverse overlap method.

Inventive Principle:

Principle #13The other way round (Inversion)

3Volume of stationary object

If magnetic fluxes overlap on common column to minimize its size, then inductor volume is reduced, but high-frequency magnetic core loss increases

Engineering Contradiction:

Improveinductor volumeVSAvoidhigh-frequency magnetic core loss

Core Design Contradiction:

Volume of stationary objectVSLoss of energy

Solution Approach 1:

The patent inverts the magnetic flux interaction from overlapping to opposing by changing the winding directions and introducing phase difference. This creates opposing magnetic fluxes that cancel each other throughout the entire magnetic core, significantly reducing high-frequency core loss while maintaining compact volume.

Inventive Principle:

Principle #13The other way round (Inversion)

Solution Approach 2:

The patent converts the potentially harmful overlapping magnetic fluxes into beneficial opposing fluxes that cancel each other out. By introducing a 180° phase difference between windings with the same winding direction, the magnetic fluxes that would normally add up and cause core loss are transformed into counteracting fluxes that reduce overall magnetic field strength and minimize core loss.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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 significantly reduces magnetic core loss and volume while maintaining high-frequency performance by offsetting high-frequency magnetic fluxes, enhancing heat dissipation, and reducing overall size.

Implementation Method 1

two windings are respectively wound on the two winding columns, wherein a line frequency current component of a current flowing through each of the two windings surrounds the winding columns in the same direction, phase difference between high-frequency current component of the current flowing through each of the two windings is 180°

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Data Source

PatentUS12451278B2Integrated inductor and power module

Publication Date: 2025.10.21 DELTA ELECTRONICS (SHANGHAI) CO LTD

AI summary

The application provides an integrated inductor and a power module. The integrated inductor includes a magnetic core, comprising: two winding columns disposed in parallel, each provided with an air gap; a first cover plate disposed under the two winding columns; a second cover plate disposed above the two winding columns, and opposite to the first cover plate; and a common column connected between the first and second cover plates, and disposed on one or both sides of the two winding columns; and two windings are respectively wound on the two winding columns, wherein a line frequency current component of a current flowing through each of the two windings surrounds the winding columns in the same direction, a phase of high-frequency current component of the current flowing through each of the two windings differs by 180°, and a coupling coefficient between the two windings is less than 0.1.