Integrated Inductor Layout for Balanced Parallel Power Conversion
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Solution Overview
Problem
In high power supply applications, parallel-connected converters with multiple magnetic elements result in increased volume, weight, and loss due to non-uniform electrical parameters leading to uneven power distribution and potential overheating or voltage/current stress.
Innovation Solution
Integration of inductors and transformers into a single magnetic element with carefully designed central and side columns and windings, ensuring uniform magnetic flux direction and phase difference between high-frequency current components to reduce volume and weight while maintaining efficient power conversion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If multiple separate magnetic elements are used in parallel-connected converters, then power conversion capability is improved, but volume and weight increase
Solution Approach 1:
The patent combines multiple magnetic elements (inductors and transformers) into a single integrated magnetic element with a shared magnetic core. The core includes multiple central columns for inductors and side columns for transformers, all integrated into one structure. This merging reduces the total volume and weight compared to using separate magnetic elements while maintaining the required power conversion capability through parallel-connected converter branches.
2Power
If multiple separate magnetic elements are used in parallel-connected converters, then power conversion capability is improved, but the number of components and volume increase
Solution Approach 1:
The patent integrates multiple magnetic elements into one unified magnetic core structure. The core contains multiple central columns (for inductors) and side columns (for transformers) that share common magnetic paths and structural support. This integration significantly reduces the total volume occupied by magnetic elements compared to using separate components, while still supporting multiple parallel converter branches for high power conversion.
Solution Approach 2:
The integrated magnetic core serves multiple functions simultaneously: it provides magnetic paths for multiple inductors (through central columns) and transformers (through side columns), structural support for all windings, and shared magnetic flux paths. This multi-functionality allows a single component to replace what would traditionally require multiple separate magnetic elements.
3Weight of stationary object
If magnetic elements are integrated into a single element, then volume and weight are reduced, but manufacturing complexity increases
Solution Approach 1:
The magnetic core is segmented into distinct functional regions: multiple central columns for inductors, side columns for transformers, and yoke sections connecting them. Each column can be independently wound and assembled. This segmentation allows for modular manufacturing where windings can be prepared separately and then assembled onto the core structure, reducing overall manufacturing complexity despite the integrated design.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement within the magnetic core, positioning inductor windings around central columns and transformer windings around side columns in different spatial zones. This dimensional organization allows multiple components to coexist in a compact integrated structure without excessive manufacturing complexity, as each winding group occupies its own designated spatial region.
4Power
If non-uniform electrical parameters are present in magnetic elements, then power distribution becomes uneven, but this leads to overheating and voltage/current stress
Solution Approach 1:
The magnetic core provides uniform magnetic properties across all central columns and side columns through consistent material selection and symmetric geometric design. Each column has matched cross-sectional areas and magnetic path lengths, ensuring uniform inductance values for all inductors and transformers. This local uniformity in magnetic properties across different regions of the core ensures even power distribution and prevents overheating or voltage/current stress on any single branch.
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 approach reduces the number and volume of magnetic elements, enhances power density, simplifies control circuits, optimizes current sharing, and improves efficiency by minimizing magnetic flux ripples and core losses.
Implementation Method 1
When a reference current flows from the first terminal of the first winding to the second terminal of the first winding, a magnetic field is generated by the reference current on the first central column and the magnetic field has a first magnetic flux direction, and a magnetic field generated by an identical reference current on the second central column has a second magnetic flux direction when the identical reference current flows from the first terminal of the second winding and to the second terminal of the second winding. The second magnetic flux direction is the same as the first magnetic flux direction
Implementation Method 2
a first operating current flowing through the first winding has a first high-frequency current component, and a second operating current flowing through the second winding has a second high-frequency current component, and a phase difference is 180 degrees between the first high-frequency current component and the second high-frequency current component
Data Source
AI summary
An integrated inductor and a power conversion module including the integrated inductor are provided. The integrated inductor includes a magnetic core, the magnetic core including two cover plates, two side columns and two central columns between the two side columns, and two windings wound around the two central columns respectively, forming two inductors. Each operating current flowing through the two windings includes a corresponding high-frequency current component, a phase difference between the high-frequency current components of the operating currents flowing through the two windings is 180 degrees.