CN113314312B - Integrated planar inductor based on magnetic core structure - Google Patents
Integrated planar inductor based on magnetic core structure Download PDFInfo
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- CN113314312B CN113314312B CN202110409520.8A CN202110409520A CN113314312B CN 113314312 B CN113314312 B CN 113314312B CN 202110409520 A CN202110409520 A CN 202110409520A CN 113314312 B CN113314312 B CN 113314312B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/24—Magnetic cores
- H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
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Abstract
The invention discloses an integrated planar inductor based on a magnetic core structure, which comprises an upper layer substrate and a lower layer substrate, wherein a first magnetic column, a second magnetic column, a third magnetic column, a fourth magnetic column, a fifth magnetic column, a sixth magnetic column, a seventh magnetic column, an eighth magnetic column, an upper layer winding structure and a lower layer winding structure are arranged between the upper layer substrate and the lower layer substrate, the upper layer winding structure is positioned above the lower layer winding structure, the upper layer winding structure and the lower layer winding structure are wound on the first magnetic column, the second magnetic column, the third magnetic column, the fourth magnetic column, the fifth magnetic column, the sixth magnetic column, the seventh magnetic column and the eighth magnetic column, and the upper layer winding structure is connected with the lower layer winding structure.
Description
Technical Field
The invention relates to an inductor, in particular to an integrated planar inductor based on a magnetic core structure.
Background
High efficiency, high power density, miniaturization, and low cost have become the development trend of industrial applications such as data centers, electric vehicles, and LED drivers. With the increase of the switching frequency, passive components such as transformers and inductors become bottlenecks that restrict the increase of the power density. The PCB copper wire is adopted as the winding, so that the profile of the magnetic core can be effectively reduced. However, the inductance value of the PCB inductor is often limited by the number of PCB layers. The existing technology is a 7.5 muH integrated planar inductor made of six layers of PCB boards, but the cost is high. There is also a method of constructing a multi-permeability distributed gap inductor structure that increases the inductance without increasing the size of the inductor, but the configuration of cores of different permeability makes the manufacturing process more complicated. It has also been investigated to arrange the windings in parallel to reduce the current by half, but the EI core has only one magnetic arm for the winding, limiting the inductance value.
Disclosure of Invention
The present invention is directed to overcoming the above-mentioned disadvantages of the prior art and providing an integrated planar inductor based on a magnetic core structure, which has the advantages of low cost, high inductance and simple structure.
In order to achieve the above object, the integrated planar inductor based on a magnetic core structure according to the present invention includes an upper substrate and a lower substrate, wherein a first magnetic pillar, a second magnetic pillar, a third magnetic pillar, a fourth magnetic pillar, a fifth magnetic pillar, a sixth magnetic pillar, a seventh magnetic pillar, an eighth magnetic pillar, an upper winding structure and a lower winding structure are disposed between the upper substrate and the lower substrate, the upper winding structure is located above the lower winding structure, and the upper winding structure and the lower winding structure are wound around the first magnetic pillar, the second magnetic pillar, the third magnetic pillar, the fourth magnetic pillar, the fifth magnetic pillar, the sixth magnetic pillar, the seventh magnetic pillar and the eighth magnetic pillar, and the upper winding structure is connected to the lower winding structure.
The upper-layer winding structure comprises a first winding, a second winding, a third winding, a fourth winding and a fifth winding, wherein one end of the first winding is opened and sleeved on the first magnetic column, the other end of the first winding is contacted with the eighth magnetic column, one end of the second winding is used as one end of the inductor, the other end of the second winding is contacted with the second magnetic column, one end of the third winding is opened and sleeved on the third magnetic column, the other end of the third winding is used as the other end of the inductor, one end of the fourth winding is opened and sleeved on the fifth magnetic column, the other end of the fourth winding is contacted with the fourth magnetic column, one end of the fifth winding is opened and sleeved on the seventh magnetic column, and the other end of the fifth winding is contacted with the sixth magnetic column.
The lower-layer winding structure comprises a sixth winding, a seventh winding, an eighth winding and a ninth winding, wherein one end of the sixth winding is opened and sleeved on the second magnetic column, the other end of the sixth winding is contacted with the first magnetic column, one end of the seventh winding is opened and sleeved on the third magnetic column, the other end of the seventh winding is opened and sleeved on the fourth magnetic column, one end of the eighth winding is opened and sleeved on the sixth magnetic column, the other end of the eighth winding is contacted with the fifth magnetic column, one end of the ninth winding is opened and sleeved on the eighth magnetic column, and the other end of the ninth winding is contacted with the seventh magnetic column;
one end of the first winding is connected with one end of the sixth winding, the second winding is connected with the other end of the sixth winding, the third winding is connected with one end of the seventh winding, one end of the fourth winding is connected with the other end of the seventh winding, the other end of the fourth winding is connected with one end of the eighth winding, one end of the fifth winding is connected with the other end of the eighth winding, the other end of the fifth winding is connected with one end of the ninth winding, and the other end of the first winding is connected with the other end of the ninth winding.
The first magnetic column, the second magnetic column, the third magnetic column, the fourth magnetic column, the fifth magnetic column, the sixth magnetic column, the seventh magnetic column and the eighth magnetic column are sequentially and uniformly distributed along the circumferential direction.
The cross sections of the first magnetic column, the second magnetic column, the third magnetic column, the fourth magnetic column, the fifth magnetic column, the sixth magnetic column, the seventh magnetic column and the eighth magnetic column are square.
The upper substrate is in a square structure.
The lower substrate is in a square structure.
The invention has the following beneficial effects:
when the integrated planar inductor based on the magnetic core structure is operated specifically, the integrated planar inductor is composed of eight magnetic columns and an upper winding structure and a lower winding structure, wherein the upper winding structure and the lower winding structure enable the magnetic flux directions of the eight magnetic columns to be distributed in a staggered mode, so that magnetic fields generated by the eight magnetic columns are mutually reinforced, the inductance value of the integrated planar inductor is further effectively improved, and the integrated planar inductor based on the magnetic core structure is simple in structure, convenient to operate and extremely high in practicability.
Drawings
FIG. 1 is a schematic view of the structure of the present invention;
FIG. 2 is a topology diagram of the present invention;
FIG. 3a is a schematic diagram of an upper layer winding structure;
FIG. 3b is a schematic diagram of a lower layer winding structure;
FIG. 3c is a magnetic flux circuit diagram of the present invention;
FIG. 4a is a diagram of a magnetoresistive model according to the present invention;
FIG. 4b is a simplified diagram of a magnetoresistive model;
FIG. 5 is a physical block diagram of an inductor;
fig. 6a is a schematic illustration of magnetic induction at g =0.2 mm;
fig. 6b is a schematic illustration of the magnetic induction at g =0.5 mm;
fig. 6c is a schematic diagram of magnetic induction at g =1 mm;
fig. 7a is a magnetic flux leakage simulation diagram when g =0.2 mm;
fig. 7b is a magnetic flux leakage simulation diagram when g =0.5 mm;
fig. 7c is a magnetic flux leakage simulation diagram when g =1 mm;
FIG. 8 is a current density distribution diagram of the present invention;
FIG. 9 is a test platform diagram of a simulation experiment;
FIG. 10a is a graph showing the variation of the gate-source voltage and the inductor current;
FIG. 10b is a graph of the efficiency of the present invention.
Wherein, 1 is a first magnetic column, 2 is a second magnetic column, 3 is a third magnetic column, 4 is a fourth magnetic column, 5 is a fifth magnetic column, 6 is a sixth magnetic column, 7 is a seventh magnetic column, 8 is an eighth magnetic column, 9 is a first winding, 10 is a second winding, 11 is a third winding, 12 is a fourth winding, 13 is a fifth winding, 14 is a sixth winding, 15 is a seventh winding, 16 is an eighth winding, and 17 is a ninth winding.
Detailed Description
In order to make those skilled in the art better understand the technical solutions of the present invention, the technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, not all of the embodiments, and do not limit the scope of the disclosure of the present invention. Moreover, in the following description, descriptions of well-known structures and techniques are omitted so as to not unnecessarily obscure the concepts of the present disclosure. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
There is shown in the drawings a schematic block diagram of a disclosed embodiment in accordance with the invention. The figures are not drawn to scale, wherein certain details are exaggerated and possibly omitted for clarity of presentation. The shapes of the various regions, layers and their relative sizes, positional relationships are shown in the drawings as examples only, and in practice deviations due to manufacturing tolerances or technical limitations are possible, and a person skilled in the art may additionally design regions/layers with different shapes, sizes, relative positions, according to the actual needs.
Referring to fig. 1, fig. 3a and fig. 3b, the integrated planar inductor based on a magnetic core structure according to the present invention includes an upper substrate and a lower substrate, and a first magnetic pillar 1, a second magnetic pillar 2, a third magnetic pillar 3, a fourth magnetic pillar 4, a fifth magnetic pillar 5, a sixth magnetic pillar 6, a seventh magnetic pillar 7, an eighth magnetic pillar 8, an upper winding structure and a lower winding structure are disposed between the upper substrate and the lower substrate, wherein the upper winding structure is located above the lower winding structure, and the upper winding structure and the lower winding structure are wound on the first magnetic pillar 1, the second magnetic pillar 2, the third magnetic pillar 3, the fourth magnetic pillar 4, the fifth magnetic pillar 5, the sixth magnetic pillar 6, the seventh magnetic pillar 7 and the eighth magnetic pillar 8, and the upper winding structure is connected to the lower winding structure.
Specifically, the upper-layer winding structure includes a first winding 9, a second winding 10, a third winding 11, a fourth winding 12, and a fifth winding 13, wherein one end of the first winding 9 is open and sleeved on the first magnetic pillar 1, the other end of the first winding 9 is in contact with the eighth magnetic pillar 8, one end of the second winding 10 is used as one end of the inductor, the other end of the second winding 10 is in contact with the second magnetic pillar 2, one end of the third winding 11 is open and sleeved on the third magnetic pillar 3, the other end of the third winding 11 is used as the other end of the inductor, one end of the fourth winding 12 is open and sleeved on the fifth magnetic pillar 5, the other end of the fourth winding 12 is in contact with the fourth magnetic pillar 4, one end of the fifth winding 13 is open and sleeved on the seventh magnetic pillar 7, and the other end of the fifth winding 13 is in contact with the sixth magnetic pillar 6.
The lower-layer winding structure comprises a sixth winding 14, a seventh winding 15, an eighth winding 16 and a ninth winding 17, wherein one end of the sixth winding 14 is opened and sleeved on the second magnetic column 2, the other end of the sixth winding 14 is contacted with the first magnetic column 1, one end of the seventh winding 15 is opened and sleeved on the third magnetic column 3, the other end of the seventh winding 15 is opened and sleeved on the fourth magnetic column 4, one end of the eighth winding 16 is opened and sleeved on the sixth magnetic column 6, the other end of the eighth winding 16 is contacted with the fifth magnetic column 5, one end of the ninth winding 17 is opened and sleeved on the eighth magnetic column 8, and the other end of the ninth winding 17 is contacted with the seventh magnetic column 7; one end of the first winding 9 is connected with one end of the sixth winding 14, the second winding 10 is connected with the other end of the sixth winding 14, the third winding 11 is connected with one end of the seventh winding 15, one end of the fourth winding 12 is connected with the other end of the seventh winding 15, the other end of the fourth winding 12 is connected with one end of the eighth winding 16, one end of the fifth winding 13 is connected with the other end of the eighth winding 16, the other end of the fifth winding 13 is connected with one end of the ninth winding 17, and the other end of the first winding 9 is connected with the other end of the ninth winding 17.
The first magnetic column 1, the second magnetic column 2, the third magnetic column 3, the fourth magnetic column 4, the fifth magnetic column 5, the sixth magnetic column 6, the seventh magnetic column 7 and the eighth magnetic column 8 are uniformly distributed in sequence along the circumferential direction; the cross sections of the first magnetic column 1, the second magnetic column 2, the third magnetic column 3, the fourth magnetic column 4, the fifth magnetic column 5, the sixth magnetic column 6, the seventh magnetic column 7 and the eighth magnetic column 8 are square; the upper substrate is of a square structure; the lower substrate is of a square structure.
For the feasibility of the invention, the inductor is used in a 30W BUCK circuit with 12V-6V, and the circuit topology is shown in figure 2.
The winding method of the coil is shown in fig. 3, and fig. 3a is a schematic diagram of an upper layer winding structure, wherein a dotted line indicates a current flow direction. Fig. 3b is a schematic diagram of the lower winding structure, wherein the dashed line indicates the current flow direction. The upper layer winding structure is connected with the lower layer winding structure through a via hole. Fig. 3c shows the magnetic flux circuit of the present invention in a top view, and as can be seen from fig. 3c, a closed magnetic flux circuit is formed between adjacent magnetic poles, and this winding method can reduce the leakage flux to the maximum.
To calculate the inductance value and the magnetic field of the inductor, a magnetoresistive model needs to be established, first, taking into account the core material: ferrite corporation's 3F36 ferrite core was chosen, which has the lowest ferrite loss at 500kHz compared to several candidates, but the saturation flux of ferrite cores is relatively small, and therefore an air gap is typically required to limit magnetic saturation, and the reluctance model of inductance is shown in fig. 4 a.
R1 is the magnetic resistance of the magnetic columns, rg is the magnetic resistance of the air gap, and R2 and R3 are the magnetic resistance between the magnetic columns. N is the number of turns per winding and il is the current flowing through the winding, the complexity of the reluctance model leads to an excessive calculation and needs to be simplified: the other reluctance is negligibly small compared to the air gap reluctance and therefore the magnetic circuit can be simplified, as shown in fig. 4 b.
Simulation experiment
The present invention was simulated using Ansys software to aid in design and analysis. As shown in fig. 5, the physical structure of the inductor requires that the air gap length of the ferrite core be in consideration of saturation flux and leakage flux. The relative permeability of the 3F36 ferrite core is 1600, the saturation magnetic flux density is 0.4T, and three schemes of the ferrite core with the air gap length of 0.2mm, the ferrite core with the air gap length of 0.5mm and the ferrite core with the air gap length of 1mm are simulated and compared.
First, the ac inductance value was simulated by using Q3D software, and as a result, as shown in table 1, it can be seen that the inductance value of the ferrite core decreases as the air gap length increases under the same conditions. In such applications, the inductance value is required to be as large as possible to reduce output current ripple and thus reduce inductance loss.
TABLE 1
As shown in fig. 6 and 7, when the airgap length is 0.2mm, the peak magnetic flux density of the magnetic core is 0.395T, the magnetic core is close to the saturation magnetic flux density under a 5A load, and the peak magnetic flux density is 0.178T and is far lower than 0.4T when the airgap length is 1mm, but the magnetic leakage is large; when the air gap length is 0.5mm, the peak magnetic induction of the magnetic core is 0.239T, and the magnetic induction and the magnetic leakage are in a proper safety margin.
A ferrite core with an air gap length of 0.5mm is selected in view of a large inductance value and a suitable magnetic flux density. The current density distribution was simulated using Ansys Maxwell magnetic software, and as a result, as shown in fig. 8, it can be seen that the current density at the magnetic pillar boundary is large due to the skin effect and proximity effect; in FIG. 6b, the magnetic flux density at the interface between the pillar and the air gap is also large, which is caused by the edge effect, and the simulation result is consistent with theory.
In order to test the performance of the integrated planar inductor, a 12-6V 30W Buck converter prototype is built, the working frequency is 500kHz, the main parameters are shown in Table 2, the experimental platform and the designed inductor are shown in FIG. 9, the inductance value measured by an Agilent E4980A bridge is 2.89 muH, and the performance is consistent with the simulation result.
TABLE 2
Fig. 10a shows the upper gate source voltage waveform measured by a voltage probe Tektronix TPP0201 with a bandwidth of 200MHz and the inductor current waveform measured by a current clamp Tektronix TCP0020 with an oscilloscope of Tektronix MDO4104C and a bandwidth of 1GHz, it can be seen that the current ripple of the inductor is small and the design is reasonable, fig. 10b shows the efficiency of the experimental prototype under different loads, it can be seen that the peak efficiency of the prototype is 95.1% and the efficiency under full load is 89.3%.
Claims (5)
1. An integrated planar inductor based on a magnetic core structure is characterized by comprising an upper layer substrate and a lower layer substrate, wherein a first magnetic column (1), a second magnetic column (2), a third magnetic column (3), a fourth magnetic column (4), a fifth magnetic column (5), a sixth magnetic column (6), a seventh magnetic column (7), an eighth magnetic column (8), an upper layer winding structure and a lower layer winding structure are arranged between the upper layer substrate and the lower layer substrate, the upper layer winding structure is positioned above the lower layer winding structure, the upper layer winding structure and the lower layer winding structure are wound on the first magnetic column (1), the second magnetic column (2), the third magnetic column (3), the fourth magnetic column (4), the fifth magnetic column (5), the sixth magnetic column (6), the seventh magnetic column (7) and the eighth magnetic column (8), and the upper layer winding structure is connected with the lower layer winding structure;
the upper-layer winding structure comprises a first winding (9), a second winding (10), a third winding (11), a fourth winding (12) and a fifth winding (13), wherein one end of the first winding (9) is opened and sleeved on the first magnetic column (1), the other end of the first winding (9) is contacted with the eighth magnetic column (8), one end of the second winding (10) is used as one end of an inductor, the other end of the second winding (10) is contacted with the second magnetic column (2), one end of the third winding (11) is opened and sleeved on the third magnetic column (3), the other end of the third winding (11) is used as the other end of the inductor, one end of the fourth winding (12) is opened and sleeved on the fifth magnetic column (5), the other end of the fourth winding (12) is contacted with the fourth magnetic column (4), one end of the fifth winding (13) is opened and sleeved on the seventh magnetic column (7), and the other end of the fifth winding (13) is contacted with the sixth magnetic column (6);
the lower-layer winding structure comprises a sixth winding (14), a seventh winding (15), an eighth winding (16) and a ninth winding (17), wherein one end of the sixth winding (14) is opened and sleeved on the second magnetic column (2), the other end of the sixth winding (14) is contacted with the first magnetic column (1), one end of the seventh winding (15) is opened and sleeved on the third magnetic column (3), the other end of the seventh winding (15) is opened and sleeved on the fourth magnetic column (4), one end of the eighth winding (16) is opened and sleeved on the sixth magnetic column (6), the other end of the eighth winding (16) is contacted with the fifth magnetic column (5), one end of the ninth winding (17) is opened and sleeved on the eighth magnetic column (8), and the other end of the ninth winding (17) is contacted with the seventh magnetic column (7);
one end of the first winding (9) is connected with one end of the sixth winding (14), the second winding (10) is connected with the other end of the sixth winding (14), the third winding (11) is connected with one end of the seventh winding (15), one end of the fourth winding (12) is connected with the other end of the seventh winding (15), the other end of the fourth winding (12) is connected with one end of the eighth winding (16), one end of the fifth winding (13) is connected with the other end of the eighth winding (16), the other end of the fifth winding (13) is connected with one end of the ninth winding (17), and the other end of the first winding (9) is connected with the other end of the ninth winding (17);
the first magnetic column (1), the second magnetic column (2), the third magnetic column (3), the fourth magnetic column (4), the fifth magnetic column (5), the sixth magnetic column (6), the seventh magnetic column (7) and the eighth magnetic column (8) are sequentially and uniformly distributed along the circumferential direction.
2. The integrated planar inductor based on the magnetic core structure as claimed in claim 1, wherein the cross-sections of the first magnetic pillar (1), the second magnetic pillar (2), the third magnetic pillar (3) and the fourth magnetic pillar (4) are square.
3. The integrated planar inductor based on magnetic core structure as claimed in claim 1, wherein the cross-sections of the fifth magnetic pillar (5), the sixth magnetic pillar (6), the seventh magnetic pillar (7) and the eighth magnetic pillar (8) are square.
4. The integrated planar inductor based on magnetic core structure as claimed in claim 1, wherein the upper substrate has a square structure.
5. The integrated planar inductor based on magnetic core structure as claimed in claim 1, wherein the lower substrate has a square structure.
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