Trans Inductor with Hiflux Core for Peak Current Reduction
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Solution Overview
Problem
Conventional inductors in high-voltage DC-DC converters for eco-friendly vehicles face issues with high peak current generation, leading to increased capacitance requirements, core saturation, and reduced inductance, which affects efficiency and electromagnetic noise.
Innovation Solution
A trans inductor with a core formed from compressible powdery Hiflux material, featuring a transformer-type structure with two coil portions wound on opposite sides, reduces peak current and prevents core saturation, thereby maintaining inductance and improving efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a ferrite core is used in a trans inductor for high current generation, then the core becomes saturated due to high peak current, but the unique properties of the magnetic substance are lost
Solution Approach 1:
The patent changes the core material parameter from conventional ferrite to a composite material containing Fe, Ni, and Al in specific proportions (Fe: 60-80 wt%, Ni: 10-30 wt%, Al: 5-15 wt%). This material composition change enables the core to withstand high peak currents without saturation, maintaining magnetic properties under high power conditions where traditional ferrite fails.
2Device complexity
If a general inductor is used in an HDC, then high peak current is generated which increases capacitance requirements and causes high noise, but the inductor structure can be simple
Solution Approach 1:
The patent employs a composite magnetic material combining Fe, Ni, and Al in specific ratios to create a core that inherently suppresses peak current. This composite material provides both the structural simplicity of a conventional inductor and the beneficial effect of peak current reduction, eliminating noise and capacitance increase issues without complicating the inductor structure.
3Quantity of substance
If a conventional inductor allows ripple current to increase in smoothing capacitor, then capacitor capacity and size must be increased, but the inductor structure remains simple
Solution Approach 1:
The patent uses a Fe-Ni-Al composite magnetic material that inherently limits ripple current magnitude. This material composition enables the use of smaller capacitance values in the smoothing capacitor while maintaining stable operation, eliminating the need for large-capacity capacitors without requiring complex inductor designs.
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 trans inductor reduces RMS current and ripple current, decreases capacitor size and capacitance, and enhances inverter efficiency by preventing core saturation, thus improving the overall performance and lifespan of components.
Implementation Method 1
a core formed of Hiflux... prevents core saturation, thereby maintaining inductance
Implementation Method 2
the core is saturated due to generation of high peak current and unique properties of a magnetic substance may be lost
Implementation Method 3
a transformer-type structure with two coil portions wound on opposite sides... reduces peak current and prevents core saturation
Data Source
AI summary
A trans inductor having a powdery magnetic substance and a power converter using the trans inductor are provided. The trans inductor and the power converter reduce peak current flowing in an inverter power module (IGBT), improve inverter efficiency, reduce output RMS current (output effective current) and reduce capacitor consumption by applying a material with properties that are resistant against current saturation instead of a core material of a conventional trans inductor employed in a power converter. Accordingly, an inductance decreasing rate due to core saturation when high current is generated is improved and current flowing in a switch device is prevented from being abruptly increased.