Integrated Inductor Structure for Common- and Differential-Mode Filtering
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Solution Overview
Problem
Inverters with separate differential-mode and common-mode inductors occupy a large area, weight, and are costly due to the separate components.
Innovation Solution
An inductor design integrating differential-mode and common-mode functions using a first and second magnetic core with a third magnetic core, allowing for both types of inductance to be generated, reducing the overall size and weight by sharing components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate differential-mode inductor and common-mode inductor are used, then both differential-mode inductance and common-mode inductance can be provided, but the device occupies large area and has large weight
Solution Approach 1:
The patent combines the differential-mode inductor and common-mode inductor into a single integrated inductor structure. The first and second windings are wound on different magnetic cores (first magnetic core and second magnetic core respectively), while the third magnetic core provides a shared magnetic path. This merging allows both differential-mode and common-mode inductance functions to be achieved in one component, reducing the overall weight compared to using two separate inductors.
Solution Approach 2:
The integrated inductor is designed to perform multiple functions simultaneously. The first winding on the first magnetic core provides differential-mode inductance, while the second winding on the second magnetic core provides common-mode inductance. The third magnetic core serves as a shared magnetic path for both windings. This multi-functional design enables a single inductor to replace what would traditionally require two separate inductors.
2Reliability
If separate differential-mode inductor and common-mode inductor are used, then both differential-mode inductance and common-mode inductance can be provided, but the device occupies large PCB area
Solution Approach 1:
The patent merges two separate inductor functions into one integrated component that occupies a single PCB footprint. By combining the differential-mode and common-mode inductors into one physical unit with shared magnetic core structures, the PCB area required is significantly reduced compared to mounting two separate inductors on the board.
Solution Approach 2:
The integrated inductor structure employs a nested arrangement where the first and second magnetic cores are positioned adjacent to each other, and the third magnetic core provides a shared magnetic path that couples both windings. This nested-like configuration allows the magnetic paths to be efficiently utilized within a compact volume, minimizing the PCB area occupation.
3Reliability
If separate differential-mode inductor and common-mode inductor are used, then both differential-mode inductance and common-mode inductance can be provided, but the device has high costs
Solution Approach 1:
The patent combines two separate inductor components into one integrated inductor, which reduces the total component count. This merging leads to lower manufacturing costs through reduced assembly steps, fewer soldering operations, and simplified supply chain management. The integrated structure also allows for more efficient use of magnetic core materials and windings.
Solution Approach 2:
The integrated inductor is designed as a universal component that provides both differential-mode and common-mode inductance functions. This multi-functionality eliminates the need to procure, store, and assemble two different inductor types, thereby reducing overall manufacturing costs and simplifying the production process.
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
The integrated inductor design reduces the size, weight, and cost of single-phase power converters by efficiently generating both differential-mode and common-mode inductance without increasing the footprint on a printed circuit board.
Implementation Method 1
When a first current (the first current is one of a differential-mode current and a common-mode current) is applied to the first winding and the second winding, a direction of a magnetic field generated by the first winding is opposite to a direction of a magnetic field generated the second winding. In this case, magnetic fluxes of the first winding and the second winding on the first middle column, the second middle column, the first side column, and the second side column cancel each other, and a part of magnetic fluxes generated by the first winding and the second winding on the third magnetic core are superimposed, so that the third magnetic core can generate inductance.
Implementation Method 2
When a second current (the second current is the other of a differential-mode current and a common-mode current) is applied to the first winding and the second winding, a direction of a magnetic field generated by the first winding is the same as a direction of a magnetic field generated the second winding. In this case, magnetic fluxes generated by the first winding and the second winding on the third magnetic core cancel each other, and magnetic fluxes generated by the first winding and the second winding on the first middle column, the second middle column, the first side column, and the second side column are superimposed, so that the first magnetic core and the second magnetic core can generate inductance.
Data Source
AI summary
A first winding is wound around a first middle column of a first magnetic core, and a second winding is wound around a second middle column of a second magnetic core. The third magnetic core is located between the first winding and the second winding, the third magnetic core has a through hole, and both the first middle column and the second middle column extend into the through hole. When a direction of a magnetic field generated by the first winding is the same as a direction of a magnetic field generated the second winding, the first magnetic core and the second magnetic core generate common-mode inductance. When a direction of a magnetic field generated by a third winding is opposite to a direction of a magnetic field generated a fourth winding, the third magnetic core generates differential-mode inductance.