Variable Coupled Inductor Magnetic Structure and Materials
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Solution Overview
Problem
Variable coupled inductors face efficiency issues in both light-load and heavy-load situations due to low inductance and high DC resistance, respectively, which affects their performance on circuit boards.
Innovation Solution
A variable coupled inductor design featuring a magnetic structure symmetric to the central line of a second protrusion between the first and second cores, combined with ferrite material for high-saturation current and copper electrodes to reduce DC resistance, enhancing initial inductance and efficiency across load conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If dual conducting wires are coupled to reduce ripple current, then the inductance becomes low, but the efficiency becomes worse in light-load situation
Solution Approach 1:
The patent introduces a magnetic structure with different magnetic permeability than the core in a specific local region (between the second protrusion and second core). This local modification creates a magnetic field concentration effect that enhances the initial inductance value without changing the overall coupled inductor structure, thereby improving light-load efficiency while maintaining the ripple current reduction benefit.
Solution Approach 2:
The patent changes the magnetic parameters by introducing a magnetic structure with specific magnetic permeability characteristics. This parameter change increases the initial inductance value of the coupled inductor, which directly improves light-load efficiency while the coupled winding structure maintains low ripple current.
2Power
If ferrite material is used to achieve high-saturation current, then heavy-load efficiency is improved, but DC resistance remains high
Solution Approach 1:
The patent employs a composite structure combining ferrite magnetic material with copper sheet electrodes. The ferrite provides high saturation current capability while the copper electrodes provide low DC resistance pathways. This composite approach simultaneously achieves both high power handling and low energy loss in heavy-load conditions.
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 improves inductance and efficiency in light-load situations while maintaining efficiency in heavy-load conditions by optimizing the magnetic structure and material selection, effectively addressing the limitations of traditional coupled inductors.
Implementation Method 1
a magnetic structure disposed between the second protrusion and the second core, wherein the magnetic structure is symmetric with respect to the central line of the second protrusion
Implementation Method 2
a first conducting wire disposed in the first conducting-wire groove; a second conducting wire disposed in the second conducting-wire groove
Implementation Method 3
the material of the variable coupled inductor of the present invention can be a ferrite material to achieve a high-saturation current
Implementation Method 4
the material of the variable coupled inductor of the present invention can be a ferrite material
Implementation Method 5
copper sheet is used as an electrode to reduce the DC resistance
Data Source
AI summary
A variable coupled inductor comprises a first core having a first protrusion, a second protrusion, a third protrusion, a first conducting-wire groove and a second conducting-wire groove on the top surface of the first core, wherein the second protrusion is disposed between the first protrusion and the third protrusion, wherein a first conducting wire is disposed in the first conducting-wire groove, and a second conducting wire is disposed in the second conducting-wire groove, wherein a second core, disposed over the first core, wherein a magnetic structure is integrally formed with the second core and protruded on the bottom surface of the second core, wherein the bottom surface of the magnetic structure is located over the top surface of the second protrusion.