Three-Phase Inductor Core Layout for Lower Loss and Smaller Modules
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Solution Overview
Problem
In high-power density modules, the volume, weight, and loss of inductors are significant, and multiple independent inductors complicate integration, making it difficult to apply to higher power modules effectively.
Innovation Solution
A three-phase inductor design with a magnetic core and windings arranged in a specific configuration to reduce magnetic flux leakage and core loss, using a magnetic core with three magnetic pillar units and windings that create a phase difference in current flow to counteract magnetic flux, improving integration and reducing volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple independent inductors are used in power modules, then each inductor can function independently, but the overall volume and weight increase significantly
Solution Approach 1:
The patent combines three separate inductors into a single integrated three-phase inductor by sharing a common magnetic core structure. The magnetic core includes three magnetic pillars arranged in a triangle, with windings wound around each pillar. This merging approach maintains the independent electrical functions of three phases while significantly reducing the overall volume compared to three separate inductors, directly resolving the contradiction between independent function and volume reduction.
Solution Approach 2:
The common magnetic core structure serves multiple functions simultaneously: it provides the magnetic path for all three phases, acts as a shared support structure, and enables magnetic coupling between phases. The single inductor structure performs the work of three independent inductors while adding the additional benefit of reduced size and improved integration,体现ing multi-functionality that resolves the volume contradiction.
2Ease of manufacture
If multiple independent inductors are used, then each inductor can be optimized independently, but the integration complexity and difficulty of application increase
Solution Approach 1:
By merging three inductors into a single integrated structure with a shared magnetic core, the patent reduces the number of separate components that need to be managed, connected, and integrated into the power module. This simplifies the overall device complexity and ease of application while maintaining the ability to optimize each phase's winding independently around its respective magnetic pillar.
3Device complexity
If traditional inductor structures are used, then the design is simple, but the core loss and volume are significant
Solution Approach 1:
The patent employs an asymmetric magnetic circuit design where the magnetic flux paths for the three phases are distributed through three separate magnetic pillars arranged in a triangle, rather than using a symmetric traditional core structure. This asymmetric distribution optimizes the magnetic flux density distribution, reduces magnetic saturation, and lowers core losses while maintaining design simplicity through the regular triangular arrangement.
Solution Approach 2:
Each magnetic pillar is specifically designed to handle the magnetic flux of its corresponding phase, creating localized optimal magnetic paths. The windings are individually wound around each magnetic pillar, allowing local optimization of each phase's magnetic circuit while maintaining overall simplicity. This local quality approach reduces core loss by preventing flux concentration and saturation in any single region.
4Power
If inductors are designed for high power density, then power output increases, but the volume and weight of inductors become more significant
Solution Approach 1:
The integration of three inductors into a single three-phase inductor achieves high power density by consolidating the magnetic circuits. The shared magnetic core allows for more efficient use of magnetic material, reducing the total volume required to achieve the same power handling capability as three separate inductors, thus resolving the contradiction between power density and volume significance.
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 design enhances the integration of inductors, reduces core loss, and minimizes volume, effectively addressing the challenges of high-power density applications by optimizing magnetic flux distribution.
Implementation Method 1
at least one winding comprising a first winding, a second winding, and a third winding; the first winding being wound on the first magnetic pillar and the second magnetic pillar of the first magnetic pillar unit, and a first current flowing through the first winding surrounds the first magnetic pillar and the second magnetic pillar of the first magnetic pillar unit in an opposite direction
Implementation Method 2
a magnetic core comprising a first cover plate, a second cover plate and at least one magnetic pillar unit, the first cover plate and the second cover plate disposed opposite to each other, the magnetic pillar unit sandwiched between the first cover plate and the second cover plate
Data Source
AI summary
The present disclosure provides a three-phase inductor and a power module. A current flowing through each inductor of the three-phase inductor comprises a power-frequency current component and a high-frequency current component. The three-phase inductor includes a magnetic core and a winding. The magnetic core includes a first cover plate, a second cover plate and a magnetic pillar unit; the winding wound on the first magnetic pillar and the second magnetic pillar of the corresponding magnetic pillar unit, and a current flowing through the winding surrounds said first magnetic pillar and said second magnetic pillar in an opposite direction.