Integrated Power Inductor Magnetic Core for Low Phase Coupling
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Solution Overview
Problem
Existing power inductors in power devices suffer from high coupling coefficients between adjacent phases, leading to significant mutual impact and reduced magnetic conductivity, which hinders miniaturization and increases costs.
Innovation Solution
The power inductor design incorporates a magnetic core with multiple magnetic columns and cover plates, forming separate magnetic circuits for each phase to reduce coupling coefficients, utilizing materials with varying permeabilities to enhance magnetic conductivity and compactness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of stationary object
If multiple power inductors are designed in an integrated manner to reduce space occupied by the power inductor in the power device, then the space occupied by the power inductor is reduced, but the coupling coefficient between inductor units of adjacent phases becomes relatively large, leading to relatively large mutual impact between inductor magnetic circuits of the inductor units of adjacent phases, thereby affecting magnetic conductivity of the power inductor
Solution Approach 1:
The magnetic core is divided into multiple independent magnetic columns (first magnetic columns, second magnetic columns, third magnetic columns) that form separate magnetic circuits for each phase. This segmentation allows each phase to have its dedicated magnetic flux path, reducing mutual coupling between adjacent phases while maintaining compact integration. The cover plates connect these segmented magnetic columns to form complete magnetic circuits for each phase independently.
2Volume of stationary object
If a plurality of power inductors are designed in an integrated manner, then the space occupied by the power inductor is reduced, but the device complexity increases due to the need for multiple magnetic columns and cover plates to reduce coupling
Solution Approach 1:
Multiple inductors of different phases are merged into a single integrated power inductor structure, sharing common components such as the cover plates and magnetic core material. The first, second, and third magnetic columns are combined in a systematic arrangement where they serve multiple phases simultaneously. This merging reduces the overall volume compared to separate inductors while managing complexity through standardized component design.
Solution Approach 2:
The cover plates serve multiple functions: they connect different magnetic columns, form magnetic circuits for multiple phases, and provide structural support for the entire integrated inductor. The magnetic columns are designed to be reusable across different phases, with the same basic structure serving multiple purposes in the integrated assembly, thereby reducing the need for phase-specific 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
This design effectively reduces coupling between adjacent phases, improving magnetic conductivity, enabling miniaturization and reducing costs while meeting power conversion requirements.
Implementation Method 1
each first magnetic column is connected between one first cover plate and the second cover plate. One end of each second magnetic column is connected between two adjacent first cover plates, and the other end of each second magnetic column is connected to the second cover plate. Each third magnetic column is located between two wire connectors of one winding, one end of each third magnetic column is connected to one first cover plate, and the other end of each third magnetic column is connected to one second cover plate.
Implementation Method 2
because an inductor unit of each phase of the power inductor includes a plurality of magnetic circuits, most of magnetic flux generated by the inductor unit of the phase may be conducted through the magnetic circuits of the inductor unit of the phase. This can effectively avoid mutual impact between inductor units of two adjacent phases in the power inductor, that is, reduce a coupling coefficient between the inductor units of two adjacent phases
Data Source
Figure 1
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Figure 3~4
AI summary
This application provides a power inductor and a power device. The power inductor includes a magnetic core and N windings, the magnetic core includes N first magnetic columns, at least N-1 second magnetic columns, N third magnetic columns, N first cover plates, and at least one second cover plate, and N is an integer greater than or equal to 2. The N first magnetic columns are sequentially arranged, and one second magnetic column is disposed between two adjacent first magnetic columns. The N windings are respectively wound around the N first magnetic columns. Two ends of each first magnetic column are respectively connected to one first cover plate and the second cover plate. One end of each second magnetic column is connected between two adjacent first cover plates, and the other end of each second magnetic column is connected to the second cover plate. Each third magnetic column is located between two wire connectors of one winding, and two ends of each third magnetic column are respectively connected to one first cover plate and the second cover plate. In the power inductor in this application, a coupling coefficient between inductor units of two adjacent phases is reduced by adding a magnetic circuit. This helps reduce costs of the power inductor.