Multi-Inductance Magnetic Structure for Decoupling and Energy Storage
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Solution Overview
Problem
Existing inductor designs for DC/DC voltage converters, such as those used in EMC filters, lack effective decoupling and energy storage capabilities, leading to inefficiencies in magnetic flux circulation and energy management.
Innovation Solution
A component comprising a magnetically conductive structure with a base, cover, and legs, where magnetic flux circulates through dedicated first legs without gaps and second legs with air gaps, allowing for separate inductances that store magnetic energy and enhance decoupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If magnetic flux circulates through a continuous path between base and cover, then decoupling between inductances is improved, but energy storage capability deteriorates
Solution Approach 1:
The magnetic circuit is segmented into two distinct types of legs: continuous legs (without air gaps) for decoupling and legs with air gaps for energy storage. This segmentation allows each path to fulfill its specific function optimally, resolving the contradiction between decoupling and energy storage capabilities.
Solution Approach 2:
Different regions of the magnetic structure are assigned different qualities: continuous magnetic paths in some legs for decoupling purposes, and paths with air gaps in other legs for energy storage. This local differentiation enables simultaneous achievement of both decoupling and energy storage functions.
2Use of energy by moving object
If air gaps are introduced for energy storage, then energy storage capability is improved, but decoupling between inductances deteriorates
Solution Approach 1:
The magnetic circuit is segmented into two distinct types of legs: continuous legs (without air gaps) for decoupling and legs with air gaps for energy storage. This segmentation allows each path to fulfill its specific function optimally, resolving the contradiction between decoupling and energy storage capabilities.
3Ease of manufacture
If a single-block structure is used, then manufacturing simplicity is improved, but magnetic flux circulation efficiency deteriorates
Solution Approach 1:
The magnetic structure is divided into separate components (base, cover, and legs) that can be manufactured independently and then assembled. This segmentation enables optimization of each component for its specific function while maintaining manufacturing simplicity through modular production.
Solution Approach 2:
The legs are designed to be inserted into or connected with the base and cover, creating a nested or interlocking structure. This approach maintains manufacturing simplicity while enabling efficient magnetic flux circulation through optimized geometric relationships between components.
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 solution provides improved decoupling and energy storage, enabling efficient magnetic flux circulation and enhanced performance in DC/DC voltage converters, particularly in applications like 12V/48V converters and hybrid/electric vehicle systems.
Implementation Method 1
a magnetic flux circulating between the base and the cover via this second leg crosses at least one air gap
Implementation Method 2
The presence of the air gap allows the storage of magnetic energy
Implementation Method 3
the electrically conductive element and the structure cooperating so as to define at least two inductors
Data Source
Figure 1~3
Figure 4~7
Figure 8~11
AI summary
The invention relates to a component (1) forming at least two inductances (12), the component (1) comprising: - a structure (2) made of a magnetically conductive material, comprising: a base (7), a cover (8), at least one first leg (9) extending continuously between the base (7) and the cover (8) and at least two second legs (10), each second leg (10) extending between the base (7) and the cover (8) so that a magnetic flux circulating between the base (7) and the cover (8) via said second leg (10) passes through at least one air gap, and - an electrically conductive element (3) defining an electrical input (4) for the component and an electrical output (5) for the component, wherein the electrically conductive element (3) and the structure (2) cooperate so as to define at least two inductances (12), each inductance (12) having a magnetic flux circulating between the base (7) and the cover (8): - in a first leg (9), and - in a second leg (10) dedicated to said inductance (12).