Magnetic Core Structure With Nonlinear Inductance for Lower Conduction Loss
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Solution Overview
Problem
Ferrite cores in inductors face issues of saturation and increased conduction loss due to reduced inductance, which are exacerbated by high power density demands, necessitating a solution to maintain power efficiency and reduce component loss.
Innovation Solution
A magnetic component design with lateral core parts having cross-sectional areas less than or equal to the first middle core part, featuring nonlinear inductance variations and varying coupling coefficients, ensuring high inductance at low currents and saturation at high currents, with even magnetic flux distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the ferrite core inductance is reduced to prevent saturation, then the saturation issue is solved, but the conduction loss increases
Solution Approach 1:
The magnetic component employs a dynamic inductance design where the effective inductance changes with operating conditions. The lateral core parts are designed to saturate at high currents, dynamically reducing the magnetic path reluctance and maintaining low conduction loss, while preserving high inductance at low currents for efficient energy storage.
Solution Approach 2:
The invention changes the magnetic circuit parameters by introducing lateral core parts with specific cross-sectional areas that are less than or equal to the middle core parts. This parameter design enables the magnetic path to transition between different states (coupled/non-coupled, saturated/non-saturated) based on current levels, optimizing both saturation resistance and conduction loss.
2Use of energy by moving object
If the inductance of the ferrite core is reduced to maintain power efficiency, then the saturation issue is solved, but the inductor current increases and conduction loss is enhanced
Solution Approach 1:
The magnetic component uses dynamic magnetic coupling through laterally extending core parts that engage or disengage based on flux levels. At high power efficiency operating points, the lateral cores remain unsaturated providing high inductance, while at excessive flux conditions they saturate to prevent core saturation, dynamically optimizing the balance between power efficiency and conduction loss.
Solution Approach 2:
The invention modifies the magnetic circuit parameters by adding lateral core extensions with controlled cross-sectional areas. These parameter changes create a magnetic path that can adapt its effective permeability based on operating conditions, enabling the system to maintain optimal power efficiency across varying load conditions without suffering from increased conduction loss.
3Manufacturing precision
If the cross-sectional area of lateral core parts is made small, then the coupling coefficient control is improved, but the magnetic flux distribution may become uneven
Solution Approach 1:
The invention applies local quality by designing lateral core parts with specific cross-sectional areas that are less than or equal to the middle core parts. This local dimensional control creates controlled magnetic coupling zones that precisely regulate flux distribution, ensuring even magnetic field patterns while maintaining accurate coupling coefficient control for differential winding configurations.
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
Reduces component and conduction losses, enhances design efficiency under high power density, and decreases iron loss while maintaining power supply performance.
Implementation Method 1
the magnetic component generates nonlinear inductance variations at different currents for achieving different coupling coefficients. Consequently, when the magnetic component operates at low current, the magnetic component maintains a non-coupled high inductance. On the other hand, when the magnetic component operates at high current, the magnetic component achieves saturation and reduced inductance by the lateral core parts
Implementation Method 2
The winding assembly includes a first winding and a second winding. The first winding is disposed around the first middle core part. The second winding is disposed around the second middle core part.
Data Source
AI summary
A magnetic component is provided. The cross-sectional area of each lateral core part of the magnetic component is less than or equal to the cross-sectional area of the first middle core part. The magnetic component generates nonlinear inductance variations at different currents for achieving different coupling coefficients. Consequently, when the magnetic component operates at low current, the magnetic component maintains a non-coupled high inductance. On the other hand, when the magnetic component operates at high current, the magnetic component achieves high saturation and reduced inductance by the lateral core parts of the magnetic component. Simultaneously, the coupling degree is increased automatically, the AC current peak is reduced, and the magnetic flux is evenly distributed on the upper cover core part or the lower cover core part. Consequently, the magnetic component has advantage of reducing the component loss and the conduction loss in the power supply.