Integrated Inductor Structure for Compact Inverter EMI Suppression
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Solution Overview
Problem
Conventional inverter systems require separate differential mode and common mode inductors, leading to increased board area occupation, low power density, and high manufacturing costs due to independent mounting and manufacturing processes.
Innovation Solution
An integrated inductor is designed by stacking a common mode magnetic core, a second magnetic core, and a third magnetic core in sequence, with windings placed between the third and second magnetic cores, forming both a common mode and differential mode inductor within a single component, reducing space and costs while minimizing copper loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate common mode inductor and differential mode inductor are used, then filtering performance is achieved, but board area occupation increases and power density decreases
Solution Approach 1:
The patent combines the common mode inductor and differential mode inductor into a single integrated inductor component. The stacked magnetic core structure allows both inductors to share the same physical space, with the first magnetic core forming the common mode inductor and the second and third magnetic cores forming the differential mode inductor. This merging reduces the total board area occupation while maintaining both filtering functions.
Solution Approach 2:
The integrated inductor serves multiple functions simultaneously: it provides both common mode interference suppression and differential mode resonance suppression. The shared winding structure and stacked magnetic cores enable a single component to perform the roles of two separate inductors, improving power density and reducing component count.
2Manufacturing precision
If separate common mode inductor and differential mode inductor are manufactured independently, then manufacturing precision is maintained, but manufacturing cost increases
Solution Approach 1:
The patent integrates the manufacturing process of common mode and differential mode inductors into a single unified process. Both inductors are manufactured simultaneously using the same magnetic core materials and winding techniques, eliminating the need for separate manufacturing operations. This reduces overall manufacturing cost while maintaining consistent quality standards through standardized production methods.
3Reliability
If separate inductors are used, then filtering function is achieved, but device complexity increases
Solution Approach 1:
The patent merges two separate inductor components into one integrated inductor with a stacked magnetic core structure. The first magnetic core, second magnetic core, and third magnetic core are stacked to form both the common mode and differential mode inductors simultaneously. This reduces component quantity and simplifies the overall device structure while maintaining both filtering functions.
Solution Approach 2:
The integrated inductor provides universal filtering capability for both common mode and differential mode interference. A single component with multiple magnetic cores and shared windings performs the functions of multiple specialized inductors, reducing device complexity and improving power density.
4Reliability
If separate inductors with independent windings are used, then inductor performance is optimized, but copper loss increases
Solution Approach 1:
The patent combines the windings of the common mode inductor and differential mode inductor into a shared winding structure. The same winding passes through the first magnetic core, second magnetic core, and third magnetic core, eliminating redundant copper material. This reduces total copper loss while maintaining the electromagnetic performance of both inductors through optimized magnetic flux paths.
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 integrated inductor effectively suppresses both differential mode resonance and common mode interference, improving power density, reducing copper loss, and enhancing the efficiency of the inverter system by sharing windings and reducing the occupied area on the circuit board.
Implementation Method 1
Each winding is located between the third magnetic core and the second magnetic core and is wound on the common mode magnetic core and the second magnetic core. The winding and the common mode magnetic core form a common mode inductor. The winding, the second magnetic core, and the third magnetic core form a differential mode inductor.
Data Source
AI summary
An inverter includes a direct current-alternating current (DC-AC) conversion circuit and a filter circuit, where the filter circuit is connected to an alternating current side of the DC-AC conversion circuit. The filter circuit includes an integrated inductor. The integrated inductor includes a common mode magnetic core, a differential mode magnetic core, and at least two windings. The differential mode magnetic core includes a second magnetic core and a third magnetic core. The common mode magnetic core, the second magnetic core, and the third magnetic core are stacked in sequence. Each winding is located between the third magnetic core and the second magnetic core and is wound on the common mode magnetic core and the second magnetic core. The at least two windings are spaced by the third magnetic core. Set as such, a product volume can be reduced while common mode interference and differential mode interference are suppressed.