Integrated Inductor Structure for Common- and Differential-Mode EMI
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Solution Overview
Problem
Existing inductor designs struggle to effectively suppress both common-mode and differential-mode interferences in power electronic systems, such as inverters, while also achieving miniaturization and reducing costs.
Innovation Solution
The integration of a common-mode inductor and a differential-mode inductor into a single, compact structure using a first magnetic core and multiple second magnetic cores with shared windings, which allows for independent operation of the common-mode and differential-mode magnetic circuits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If separate common-mode inductor and differential-mode inductor are used, then interference suppression is effective, but device complexity and occupied space increase
Solution Approach 1:
The patent combines a common-mode inductor and a differential-mode inductor into a single integrated structure. The first magnetic core forms the common-mode inductor, while the first and second magnetic cores together form the differential-mode inductor. This merging allows both interference suppression functions to be achieved in one device, reducing overall complexity and occupied space while maintaining effective suppression of both common-mode and differential-mode interferences.
Solution Approach 2:
The integrated inductor structure serves multiple functions simultaneously. The first magnetic core provides common-mode inductance for suppressing common-mode interference, while the combination of first and second magnetic cores provides differential-mode inductance for suppressing differential-mode interference. This multi-functionality eliminates the need for separate inductors and reduces the overall number of components required.
2Object-affected harmful factors
If separate common-mode inductor and differential-mode inductor are used, then interference suppression is effective, but occupied board space increases
Solution Approach 1:
The patent merges two separate inductors into one integrated structure that occupies a single footprint on the circuit board. The first magnetic core and the first and second magnetic cores are arranged in a compact configuration where the second magnetic core is positioned adjacent to the first magnetic core, sharing common windings. This merging significantly reduces the occupied board space compared to using two separate inductors while maintaining effective interference suppression.
Solution Approach 2:
The integrated inductor structure employs a nested arrangement where the first and second magnetic cores are positioned in close proximity, sharing common windings and magnetic path sections. This nested configuration allows the differential-mode inductor to utilize the space of the common-mode inductor efficiently, minimizing the overall footprint on the circuit board.
3Object-affected harmful factors
If separate common-mode inductor and differential-mode inductor are used, then interference suppression is effective, but copper loss increases
Solution Approach 1:
The patent combines the common-mode and differential-mode inductors into a single structure that shares common windings. The windings around the first magnetic core serve both the common-mode inductor and the differential-mode inductor, eliminating the need for duplicate winding materials. This sharing of windings significantly reduces copper loss while maintaining effective suppression of both common-mode and differential-mode interferences.
Solution Approach 2:
The windings in the integrated inductor structure serve multiple functions simultaneously. The same windings provide inductance for both the common-mode inductor (with the first magnetic core) and the differential-mode inductor (with the first and second magnetic cores). This multi-functionality reduces the total amount of copper material required, thereby reducing copper loss and improving overall efficiency.
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 integrated inductor design effectively suppresses both common-mode and differential-mode interferences, reduces copper loss, and minimizes occupied board space, thereby enhancing the efficiency and power density of inverter systems.
Implementation Method 1
each winding passes through the first through hole and one corresponding second through hole, so that each winding is wound around the first magnetic core and one second magnetic core, the at least two windings and the first magnetic core form a common-mode inductor, and the at least two windings and the at least two second magnetic cores form a differential-mode inductor
Data Source
AI summary
A integrated inductor includes a first magnetic core, at least two second magnetic cores, and at least two windings. The first magnetic core includes a first surface and a second surface that are opposite to each other in a first direction. The second magnetic cores are disposed in the first direction on a side that is of the first surface and that is away from the second surface. The winding is wound around the first magnetic core and the second magnetic core. The second magnetic core includes a first part and a second part. Along the first direction and on a side that is of the first surface and that is opposite to the second surface, the first part is located between the winding and the first surface, and the second part is located on side that is of the winding and that is away from the first surface.