Sendust Core Coupled Inductor for High Flux Density
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Solution Overview
Problem
Conventional coupled inductors face challenges in achieving high saturated flux density and reducing reactor loss, especially in large-current applications, due to limitations in core materials like ferrite and dust cores, which result in increased size, heat generation, and ripple current.
Innovation Solution
A coupled inductor design utilizing a sendust core with a maximum differential permeability of at least 30 and edgewise winding, which allows for a compact structure with reduced core loss and ripple current, and enhanced heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If ferrite core is used to achieve high magnetic permeability, then inductance value increases, but saturated flux density decreases and core size must be increased
Solution Approach 1:
The patent uses a composite core structure combining ferrite material with high magnetic permeability (μ≥1000) and dust core material with high saturated flux density (≥1.0 T). This composite approach allows the core to simultaneously achieve high inductance from the ferrite component and high flux density capacity from the dust core component, resolving the contradiction between magnetic permeability and saturated flux density.
2Quantity of substance
If large gap is provided in ferrite core to decrease effective magnetic permeability, then saturated flux density improves, but leakage flux increases and initial inductance value decreases
Solution Approach 1:
The dust core material in the composite structure inherently provides high saturated flux density (≥1.0 T) without requiring large gaps. This eliminates the need for large gap adjustments that would otherwise be necessary in pure ferrite cores, thereby avoiding the associated problems of leakage flux and reduced initial inductance while maintaining high flux density capability.
Solution Approach 2:
The patent applies different material properties to different parts of the core structure - ferrite material for high permeability regions and dust core material for high flux density regions. This local differentiation allows optimization of each region's function, achieving both high initial inductance and high saturated flux density without compromising overall performance.
3Quantity of substance
If dust core is used to achieve high saturated flux density, then core size decreases, but core loss increases and heat generation occurs
Solution Approach 1:
The composite core combines dust core material (high saturated flux density ≥1.0 T) with ferrite material (low core loss characteristics). The ferrite component contributes low loss properties while the dust core component provides high flux density capability, achieving a balance that reduces overall core loss while maintaining high saturated flux density.
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 sendust core-based coupled inductor effectively manages saturated flux density and core loss, reducing reactor size and loss while maintaining a high initial inductance value, and achieving efficient heat dissipation.
Implementation Method 1
two coils wound around one core, and allow currents to flow through the two coils, respectively, so as to generate magnetic fluxes
Implementation Method 2
an annular core including a sendust core having a maximum differential permeability that is equal to or greater than 30
Data Source
AI summary
A coupled inductor comprises an annular core 1 and coils 2a, 2b wound around the core. The annular core 1 includes a sendust core having a maximum differential permeability that is equal to or greater than 30.