Integrated Vertical Inductor for High Leakage and Automation
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Solution Overview
Problem
Existing integrated inductors face challenges in miniaturization, automation, and achieving high leakage inductance values due to limitations in core designs such as Toroidal, ET, UT, UU, EE/EI types, which result in increased volume and reduced high-pot test withstand voltage.
Innovation Solution
An integrated vertical inductor design featuring a bobbin with a central opening and separate spool parts for winding, utilizing magnetic core pieces and an intermediate flange for connecting bars, allowing for automatic winding and increased core utilization, thereby integrating common-mode and differential-mode inductance without the need for separate differential-mode elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If Toroidal core is used to produce closed magnetic path, then magnetic efficiency is improved, but leakage inductance cannot be made high and automated winding is difficult
Solution Approach 1:
The inductor is divided into two separate winding portions (first and second winding portions) wound on different spools, allowing each to be independently wound using automated equipment while maintaining high leakage inductance through their spatial separation and differential winding directions
2Reliability
If ET type or UT type core is used, then inductance function is achieved, but bobbin must be split into two parts requiring manual line management
Solution Approach 1:
The magnetic core is segmented into first and second magnetic cores that can be independently positioned and fixed to the spools, enabling automated winding processes while maintaining the necessary magnetic circuit functionality for high leakage inductance
Solution Approach 2:
Spacers are introduced as intermediary elements to maintain precise spacing between the first and second magnetic cores, ensuring proper magnetic coupling and high leakage inductance while facilitating automated assembly processes
3Volume of moving object
If UU type core is changed to vertical design, then space utilization is improved, but spacing between bottom core and pins becomes too short causing Hi-pot test failure
Solution Approach 1:
The design transitions from horizontal to vertical orientation, arranging the first and second winding portions stacked vertically on separate spools, which improves space utilization while maintaining adequate insulation spacing through the vertical dimension and intermediate flange separation
4Extent of automation
If EE/EI type core is used with two winding groups on side columns, then automation degree is improved, but overall space is sacrificed
Solution Approach 1:
The windings are segmented into two separate winding portions on different spools rather than two groups on the same core, enabling automated winding while concentrating the structure vertically to reduce overall footprint and improve space utilization
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 achieves high common-mode and differential-mode inductance values with reduced size and cost, enhancing EMI filter performance and automation while maintaining safety features, with common-mode inductance over 5 mH and differential-mode inductance over 500 μH, and reduces the occupied area on a printed circuit board by 60%.
Implementation Method 1
A first coil unit (20) comprising windings of first wire (201) is wound on the first spool part (111). A second coil unit (30) comprising windings of second wire (301) is wound on the second spool part (112)
Data Source
AI summary
An integrated vertical inductor includes a bobbin having an elongated, hollow tube, an upper flange disposed at an upper end of the elongated, hollow tube, and a base structure integrated with a lower end of the elongated, hollow tube. The elongated, hollow tube comprises a central opening extending along its longitudinal direction. The base structure comprises a lateral opening communicating with the central opening. A first magnetic core piece is installed in the central opening of the elongated, hollow tube. A second magnetic core piece is juxtaposed with the first magnetic core piece. A plurality of electrodes is disposed on a bottom surface of the base structure.