Uncoupled Multi-Phase Inductor with Segmented Iron Core
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Solution Overview
Problem
Conventional inductor designs occupy excessive space, limiting the achievement of high power density in electronic devices due to magnetic coupling interference between discrete components, and multi-phase inductor configurations are rare and inefficient.
Innovation Solution
An uncoupled multi-phase inductor design featuring a primary iron core with grooves and middle cylinders, secondary iron cores, and metal strip coils, which operate independently with air gaps to minimize coupling and reduce overall volume, allowing multiple inductors to be integrated into a single device with extreme low coupling coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If discrete inductor components are used with spacing between them, then magnetic coupling interference is reduced, but the overall device volume increases
Solution Approach 1:
The patent combines multiple discrete inductor components into a single integrated multi-phase inductor device. The primary iron core with multiple grooves accommodates multiple secondary iron cores and metal strip coils, merging what would traditionally be separate components into one unified structure, thereby reducing overall device volume while maintaining functional independence through magnetic circuit design
Solution Approach 2:
The primary iron core is segmented into multiple grooves, each housing a separate secondary iron core and metal strip coil combination. This segmentation allows each phase to operate independently with controlled magnetic coupling, achieving low interference between phases while maintaining a compact integrated structure
2Volume of moving object
If multiple inductors are mechanically bonded in one device, then space is saved, but magnetic coupling interference increases and power density is not sufficiently improved
Solution Approach 1:
The patent applies different magnetic circuit configurations to different phases within the same device. By designing specific magnetic paths for each phase through the primary and secondary iron cores, and using metal strip coils with specific geometries, each phase achieves optimal local magnetic properties that minimize mutual interference while maintaining compact integration
Solution Approach 2:
The primary iron core acts as an intermediary structure that mediates between multiple secondary iron cores. The magnetic circuit design through the primary core controls and regulates the magnetic coupling between phases, transforming what would be uncontrolled interference into controlled magnetic interaction that maintains low coupling coefficients
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
This design significantly reduces space usage, increases power density, and enhances performance by enabling multiple inductors to operate independently without interference, effectively addressing the limitations of conventional inductor configurations.
Implementation Method 1
a plurality of metal strip coils (5, 6 and 7) are correspondingly disposed in the grooves (11, 12 and 13) and among the plurality of secondary iron cores (2, 3 and 4)
Implementation Method 2
The primary iron core and the plurality of secondary iron cores are ferrite materials or soft magnetic materials
Implementation Method 3
The uncoupled multi-phase inductor achieves integrating a number of inductors into one device by introducing a middle cylinder between the groove of a primary iron core and another groove and other components
Data Source
AI summary
The disclosure is related to an uncoupled multi-phase inductor that includes a primary iron core, multiple secondary iron cores, multiple metal strip coils and multiple sheet members. The primary iron core includes multiple grooves, in which multiple middle cylinders are correspondingly installed. The middle cylinders in the primary iron core, the secondary iron cores in the grooves, and the metal strip coils are assembled. The sheet members are also integrated in the assembly for forming one single device with two or more inductors. For reaching a requisite inductance, the inductors administrate air gaps among the primary iron core and the secondary iron cores by the sheet members. The multi-phase inductor shares the middle cylinder with the primary iron core as one device so as to increase power density since the space can be saved. The device integrated with the two or more inductors has an extreme low coupling coefficient.