Nested Coupled Inductor Structure for High Power Density
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Solution Overview
Problem
Existing coupled inductors have low inductive coupling due to incomplete contact between the magnetic core and conductive coils, leading to low power density and inadequate heat dissipation.
Innovation Solution
The inductor design features a magnetic core with embedded conductive coil assemblies, where an inner conductive coil is nested within an outer conductive coil, achieving a high coupling coefficient of over 0.9 through close spacing and integration via a molding process with magnetic powder.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If traditional assembled inductors are used with ferrite magnetic cores and conductive coils, then the structure is simple to manufacture, but the inductive coupling is low and power density is insufficient
Solution Approach 1:
The patent merges the magnetic core and conductive coils into a single integrated inductor component. The first and second conductive coils are wound around the same magnetic core, creating a unified structure that achieves high inductive coupling (coupling coefficient greater than 0.95) while maintaining manufacturing feasibility through standardized assembly processes.
Solution Approach 2:
The patent employs a nested configuration where the first conductive coil and second conductive coil are wound around the same magnetic core in a concentric manner. This nested arrangement maximizes the magnetic coupling between coils while maintaining a compact structure, achieving both high coupling coefficient and space efficiency.
2Power
If traditional assembled inductors are used, then manufacturing is simpler, but heat dissipation is insufficient and power density is low
Solution Approach 1:
The patent combines multiple functional elements (magnetic core, first conductive coil, second conductive coil) into a single integrated inductor structure. This merging increases power density by maximizing the utilization of magnetic flux and coil interaction, while the standardized assembly process maintains manufacturing ease through pre-fabricated components and systematic assembly procedures.
3Loss of energy
If coils are spaced further apart for manufacturing ease, then assembly is simpler, but coupling coefficient decreases
Solution Approach 1:
The patent uses a nested winding configuration where the first and second conductive coils are wound around the same magnetic core in close proximity. This nested arrangement achieves a coupling coefficient greater than 0.95 by minimizing the spacing between coils while maintaining their electrical independence, thereby maximizing magnetic coupling without requiring excessive coil length or complex positioning.
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 design enhances inductive coupling, reduces power loss, improves heat dissipation, and increases power density, while also simplifying manufacturing and reducing interference between coil assemblies.
Implementation Method 1
the inner conductive coil and the outer conductive coil are spaced apart at a distance closed enough to obtain a coupling coefficient of more than 0.9
Data Source
AI summary
An inductor provided in the present invention, includes a magnetic core and one or more conductive coil assembly embedded in the magnetic core; each conductive coil assembly comprises an inner conductive coil and an outer conductive coil surrounding the inner conductive coil. The inner conductive coil is enclosed in the outer conductive coils to form an inner and outer nested structure; the inner conductive coil and the outer conductive coil are arranged in parallel and spaced apart at a distance therebetween closed enough to obtain a coupling coefficient of more than 0.9.