Integrated Inductor Assembly with Magnetic Core Opening
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Solution Overview
Problem
Existing integrated magnetic assemblies are not adequately configured to permit multiple inductors to be manufactured on a single structure while operating independently, leading to increased component count and reduced power density in high-density power electronic circuits.
Innovation Solution
An integrated inductor assembly with a magnetic core having an opening that allows two inductors to be inductively coupled, each with a shorting segment positioned within the opening, enabling independent operation and minimizing mutual inductance by using a magnetic core with core bridges for shared flux paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If multiple inductors are integrated on a single magnetic core structure, then power density and component integration are improved, but independent operation of each inductor becomes difficult to achieve
Solution Approach 1:
The magnetic core is segmented into multiple distinct regions or sections, each capable of supporting an independent inductor. This segmentation allows each inductor to function independently while being integrated on the same core structure, resolving the contradiction between integration and independent operation.
Solution Approach 2:
Different regions of the magnetic core are designed with locally optimized properties to support specific inductor functions. Each local region can be tailored for independent operation while contributing to the overall integrated structure, enabling both high integration and independent functionality.
2Adaptability or versatility
If separate cores are used for multiple independently operating inductors, then independent operation is achieved, but component count and circuit density are reduced
Solution Approach 1:
Multiple inductors that require independent operation are merged onto a single integrated magnetic core structure. The core design incorporates multiple functional regions that can operate independently, thereby reducing the total component count while maintaining independent operation capability for each inductor.
Solution Approach 2:
The magnetic core is designed as a universal structure that can simultaneously support multiple inductors with independent operation. This multi-functional core serves as a platform for several inductors, each capable of independent operation, thereby reducing component count while maintaining versatility.
3Quantity of substance
If multiple inductors are integrated on a single core, then power density is improved, but mutual inductance and energy losses increase
Solution Approach 1:
The magnetic core is segmented into distinct regions with magnetic shielding or isolation between them. This segmentation reduces mutual inductance between integrated inductors by preventing magnetic flux from one inductor from coupling with adjacent inductors, thereby reducing energy losses while maintaining high power density.
Solution Approach 2:
Magnetic shielding materials or isolation structures are introduced as intermediaries between integrated inductors on the same core. These intermediaries block or redirect magnetic flux paths, reducing unwanted mutual inductance and energy losses between adjacent inductors while allowing the inductors to remain integrated on a single core 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 allows for compact, high-density power electronic circuits with reduced component count and energy losses when inductors operate jointly, while maintaining independent functionality.
Implementation Method 1
The first inductor includes a first conductive winding inductively coupled to the magnetic core. The second inductor includes a second conductive winding inductively coupled to the magnetic core.
Implementation Method 2
The first conductive winding includes a first shorting segment positioned within the opening. The second conductive winding includes a second shorting segment positioned within the opening. The first and second inductors are configurable to operate independently of one another.
Data Source
AI summary
An integrated inductor assembly is provided. The integrated inductor assembly includes a magnetic core, a first inductor, and a second inductor. The magnetic core has a first side, an opposing second side, and an opening defined within the magnetic core. The opening extends into the magnetic core from at least one of the first side and the second side. The first inductor includes a first conductive winding inductively coupled to the magnetic core. The first conductive winding includes a first shorting segment positioned within the opening. The second inductor includes a second conductive winding inductively coupled to the magnetic core. The second conductive winding includes a second shorting segment positioned within the opening. The first and second inductors are configurable to operate independently of one another.