Single Core Cross-Coupled Multi-Phase Inductor Design
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Solution Overview
Problem
Power converters in electric vehicles face inefficiencies due to large sizes and ripple currents, leading to increased core losses and electromagnetic compatibility issues, which are exacerbated by uneven coupling in conventional multi-phase inductors.
Innovation Solution
A cross-coupled multi-phase inductor design featuring a single core with adjacent windings comprising a main winding and a coupled winding, where the sub-windings are disposed on opposing sides of the core to enhance coupling, resulting in balanced phase currents and reduced core losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional multi-phase inductors are used with multiple separate cores, then the inductor can handle higher power, but the device size and core losses increase
Solution Approach 1:
The patent combines multiple inductor phases onto a single core structure, merging what would traditionally be separate cores into one integrated magnetic component. This consolidation reduces the overall device volume while maintaining the power handling capability of multi-phase inductors, directly resolving the contradiction between power capacity and size.
Solution Approach 2:
The single core is designed to serve multiple functions simultaneously, supporting multiple windings for different phases while providing magnetic coupling between them. This multi-functional core design enables the inductor to handle multiple phases of power conversion within a single structural element, achieving high power capability without proportional increases in size.
2Productivity
If conventional multi-phase inductors are used, then power conversion is enabled, but ripple currents and core losses increase due to uneven coupling
Solution Approach 1:
The patent introduces asymmetric positioning of windings on the single core, with specific windings placed at different locations to create controlled magnetic coupling relationships. This asymmetric arrangement optimizes the coupling between phases, balancing the magnetic flux distribution and reducing uneven coupling effects that cause ripple currents and core losses, while maintaining power conversion capability.
3Volume of stationary object
If single core multi-phase inductors are used, then device size is reduced, but manufacturing complexity increases due to winding requirements
Solution Approach 1:
The patent segments the winding structure into distinct sections, each associated with specific phases, while maintaining their integration on a single core. This segmentation approach simplifies the manufacturing process by allowing systematic winding of each phase section independently, reducing the overall complexity compared to trying to wind all phases simultaneously or using multiple separate cores.
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 cross-coupled multi-phase inductor design improves converter efficiency, reduces ripple currents, and enhances electromagnetic compatibility by achieving more balanced current flow and minimizing core losses, leading to a more compact and reliable power conversion system.
Implementation Method 1
The first and second sub-windings of the main winding may be disposed on first opposing sides of the single core. The opposing sides may be diametrically opposite or substantially diametrically opposite each other as described hereinafter. The first and second sub-windings of the coupled winding may also be disposed on second opposing sides of the single core and the first and second sub-windings of the main winding may be cross-coupled with the first and second sub-windings of the coupled winding.
Data Source
AI summary
A cross-coupled multi-phase inductor that includes a single core and pairs of adjacent windings wound on the single core. Each member of an adjacent pair includes a first sub-winding and a second sub-winding which extends from the first sub-winding and each member is cross-coupled with the other member of the pair such that the first and second sub-windings of each member of the adjacent pair are disposed diametrically opposite or substantially diametrically opposite each other on the single core. This results in reducing core losses and increasing power conversion efficiency of the cross coupled multi-phase inductor.