CN114337247B - Integrated EMI filter structure based on flexible metal foil material and design method thereof - Google Patents
Integrated EMI filter structure based on flexible metal foil material and design method thereof Download PDFInfo
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Abstract
The invention provides an integrated EMI filter structure based on flexible metal foil material and a design method thereof, wherein an EE type magnetic core with a three-winding column structure is adopted, a side column is wound by a conventional winding to form a common-mode winding, a middle column is wound by flexible metal foil to form a differential-mode winding, and meanwhile, a Y capacitor is integrated; the basic unit of the flexible metal foil winding consists of L, N, G three wires, wherein the L wire, the GND wire and the N wire are insulated by a dielectric layer. On the basis of simplifying the design and reducing the cost, the structural capacitance is increased by utilizing the advantages of the flexible material. Meanwhile, the flexibility of the flexible material is exerted, the applicability of the same EMI filter integrated structure is widened, and different requirements of LC type, tau type, pi type, T type filters and the like can be met through different wiring modes.
Description
Technical Field
The invention belongs to the technical field of filter design, and particularly relates to an integrated EMI filter structure based on flexible metal foil materials and a design method thereof.
Background
The problem of electromagnetic interference (electromagnetic interference, EMI) is more pronounced under the drive of the development of high frequency and miniaturization of power electronic converters, and therefore, EMI filters become an important component of power electronic systems, and the optimal design thereof has a profound effect on future industrial applications.
In general, a passive EMI filter is a combination of one or several filter inductors and several filter capacitors, and if the filter is constructed by using discrete components, more devices and a larger area are required, so it is very significant to discuss the efficient integration of the filter. The traditional integration method mainly comprises the steps of magnetic integration, winding common-mode inductance on a magnetic material with high magnetic conductivity, and integrating differential-common mode inductance by using leakage inductance of the common-mode inductance as a differential-mode component. The integration scheme has the advantages that winding is simple, but decoupling analysis is difficult between differential-mode inductance, differential-mode inductance is difficult to quantitatively control as leakage inductance, and the inductance is often limited by the common-mode inductance. In recent years, in order to facilitate the integrated design of the whole power electronic converter circuit, a filter integrated structure based on a planar coil and a planar magnetic core is generated, and the integrated scheme combines a multilayer board technology to integrate a differential common mode inductance and a structural capacitance, so that the structure is more compact than the former scheme, but the planar inductance is mainly increased by transversely expanding the planar coil, the structural capacitance is mainly influenced by an interlayer distance and an interlayer medium, and the occupied area of a rigid material is obviously increased along with the increase of the inductance due to the weak plasticity of the rigid material.
As shown in fig. 1 of the specification, for the conventional differential-common mode integration scheme (scheme one):
the traditional differential-common mode integration scheme utilizes different flow directions of differential-common mode current to construct magnetic integration, when L, N wires of common mode windings with equal turns are wound on two sides of an annular winding and flow into the common mode current, magnetic fluxes generated by the windings on the two sides in a magnetic core are in the same direction, and the magnetic fluxes can form a loop in the magnetic core, so that larger common mode inductance can be induced. When L, N line flows into differential mode current, magnetic flux generated by windings on two sides in the magnetic core is opposite, and the magnetic flux forms a loop from outside air, namely leakage inductance is used as differential mode inductance. The integration method only considers magnetic integration, the common differential mode inductance is 0.5-2% of the common mode inductance, the differential mode inductance is difficult to quantitatively design, and the differential mode inductance is influenced by the common mode inductance, the common mode winding method and the opening angle to a great extent, so that the consistency of the inductance is poor.
As shown in fig. 2 of the specification, for the existing planar integrated EMI filter structure (scheme two):
the planar integrated EMI filter is based on PCB winding layout, a planar magnetic core is used for constructing a differential common mode inductance, an X capacitance and a Y capacitance are constructed by utilizing an interlayer structure capacitance, and a calculation formula of the capacitance is as follows, wherein epsilon is as follows 0 Is air dielectric constant epsilon r The relative dielectric constant of the medium between the PCB windings is S the facing area between the PCB windings, and d the facing distance between the layers where the PCB windings are located.
In the PCB layout, the dielectric material between layers is generally FR4, the relative dielectric constant is 4.4, the distance between layers is limited by the process and is generally more than 0.1mm, the opposite area between PCB windings is limited by the distance between the planar magnetic core and the windings on the same layer, and the cost and the complexity of the multilayer board also reduce the practicability of the scheme. Therefore, although such methods integrate a magnetic field and an electric field, the electric field integration degree for the EMI filter is not high due to the limitation of a rigid material and the like.
According to the previous analysis, the scheme has the main defects that the differential mode sensing quantity and the common mode sensing quantity have a coupling relation, quantitative analysis on the differential mode sensing quantity is difficult, the differential mode sensing quantity is often limited by the common mode sensing quantity and a winding method thereof, and the integration of a magnetic field is only and the integration of an electric field is absent. The second main disadvantage is that the integration of the electric field is limited by the PCB material and the process is not high, and the filter is formed by the multi-layer board, which increases the design complexity and the manufacturing cost.
Disclosure of Invention
Considering that the EMI filter integration scheme based on the flexible metal foil material can integrate an electric field and a magnetic field simultaneously, and is higher than a planar integration scheme in terms of flexibility and plasticity, the invention aims to provide an EMI filter structure integrated on the basis of the flexible metal foil material and a design method thereof. And secondly, the integration of the electric field is deeply optimized on the basis of the scheme II, and the structural capacitance is increased by utilizing the advantages of the flexible material on the basis of simplifying the design and reducing the cost. Meanwhile, the flexibility of the flexible material is exerted, the applicability of the same EMI filter integrated structure is widened, and different requirements of LC type, tau type, pi type, T type filters and the like can be met through different wiring modes.
The invention adopts the following technical scheme:
an integrated EMI filter structure based on flexible metal foil material, characterized by: adopting an EE type magnetic core with a three-winding column structure, winding a side column by using a conventional winding to form a common-mode winding, winding a middle column by using a flexible metal foil to form a differential-mode winding, and integrating a Y capacitor; the basic unit of the flexible metal foil winding consists of L, N, G three wires, wherein the L wire, the GND wire and the N wire are insulated by a dielectric layer.
Further, when the common mode current flows, the common mode magnetic fluxes generated by the side column L, N lines are in the same direction, the common mode magnetic fluxes generated by the middle column L, N lines are offset, and when the differential mode current flows, the differential mode magnetic fluxes generated by the side column L, N lines are offset, and the differential mode magnetic fluxes generated by the middle column L, N lines are in the same direction.
Further, in the practical application of the EMI filter, the structure of the EMI filter is determined according to the principle of impedance mismatch.
Further, the joints of the first windings of the common-mode windings comprise L1, L2, N1 and N2, and the joints of the second windings comprise L3, L4, N3 and N4; the joint of the third winding of the differential mode winding comprises L5, L6, N5 and N6, and the joint of the fourth winding comprises L7, L8, N7 and N8; and different filters with different structures are obtained through different connection modes of the connectors.
Further, the flow direction of common mode current is taken as a leading, L1 and N1 are taken as input interfaces, L2 and L3 are connected with each other, N2 and N3 are connected with each other, L4 and L5 are connected with each other, N4 and N6 are connected with each other, L6 and L7 are connected with each other, N5 and N8 are connected with each other, and L8 and N7 are taken as output interfaces, so that the LC or tau-type filter is obtained.
Further, the common mode current flow direction is taken as a leading, L5 and N6 are taken as input interfaces, L6 is connected with L1 and N5 is connected with N1, L2 is connected with L3 and N2 is connected with N3, L4 is connected with L7 and N4 is connected with N8, and L8 and N7 are taken as output interfaces, so that the pi-type filter is obtained.
Further, the flow direction of common mode current is taken as a leading, L1 and N1 are taken as input interfaces, L2 is connected with L5, N2 is connected with N6, L6 is connected with L7, N5 is connected with N8, L8 is connected with L3, N7 is connected with N3, and L4 and N4 are taken as output interfaces, so that the T-shaped filter is obtained.
Further, the window size of the magnetic core is considered during the magnetic core model selection, and a preliminary structural capacitance estimation is made according to the window size, wherein the estimation basis is as follows:
1. according to the structural capacitance value of the required design, the dielectric constant of the insulating layer material and the thickness of the insulating layer are used, and the area of the required flexible metal foil is estimated;
2. firstly, calculating the number of turns of flexible metal foil which can be wound down by a magnetic core window according to the thickness tau of a basic unit of the flexible metal foil winding, and considering the allowance width required by winding a common mode winding by a side column during calculation;
3. according to the number of turns of the flexible metal foil to be wound and parameters of a middle column of the magnetic core, the length of the flexible metal foil required to be wound is estimated, according to the height of the magnetic core, the width of the flexible metal foil is given, the length multiplied by the width is calculated, the right area of the structure capacitor is obtained, whether the structure capacitor value meets the requirement is calculated reversely according to the obtained estimated parameters, and if not, the model selection is continued until a proper magnetic core is obtained.
Further, in winding turns and air gap designs, on the one hand, the differential mode turns limit determined in the core selection is considered, and on the other hand, the core cannot be saturated in the inflow of differential mode current is considered; a calculation formula of differential mode inductance and a constraint formula of maximum magnetic density:
wherein N is dm For the number of turns of the differential mode winding, u 0 For air permeability, ae is the effective cross-sectional area of the center leg of the core used, l qx For the length of the air gap opened, I pk L is the peak current in the circuit dm And B m For differential mode inductance and maximum magnetic density,bs is the saturation density of the core.
In the development of integration of an EMI filter, the original magnetic integration method is difficult to quantitatively design the inductance of a differential mode inductance, and the electric integration method is limited by the plasticity problem of a rigid material, so that the integration degree is not high.
Drawings
The invention is described in further detail below with reference to the attached drawings and detailed description:
FIG. 1 is a schematic diagram of a conventional differential-common mode integration scheme (scheme one) of the prior art;
FIG. 2 is a schematic diagram of a prior art planar integrated EMI filter (scheme II);
FIG. 3 is a schematic diagram of an EMI filter based on flexible metal foil according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of the basic unit structure and equivalent circuit of a flexible metal foil winding according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of an EMI filter patch port based on a flexible metal foil in accordance with an embodiment of the present invention;
FIG. 6 is a schematic diagram of an equivalent circuit structure of an LC or tau-type filter constructed in accordance with an embodiment of the present invention;
FIG. 7 is a schematic diagram of an equivalent circuit of a pi-filter constructed in accordance with an embodiment of the present invention;
FIG. 8 is a schematic diagram of an equivalent circuit of a T-shaped filter constructed according to an embodiment of the present invention;
FIG. 9 is a schematic thickness illustration of a flexible metal foil winding base unit in accordance with an embodiment of the present invention;
FIG. 10 is a schematic diagram of the dimensions of an embodiment of the present invention.
Detailed Description
In order to make the features and advantages of the present patent more comprehensible, embodiments accompanied with figures are described in detail below:
as shown in fig. 3 to 10, the flexible metal foil-based EMI filter designed in this embodiment specifically includes the following technical contents:
in combination with the differential-common mode magnetic integration method of the first scheme, the electric field integration method of the second scheme provides an EMI filter integration method of flexible metal foil. In the design of a general EMI filter, the Y capacitance is often easy to integrate in nF magnitude, and the X capacitance is often difficult to integrate in uF magnitude, so as shown in fig. 3, in the magnetic core of the three-winding post structure, the side post uses a conventional winding to wind a common mode winding, the middle post uses a flexible metal foil to wind a differential mode winding to integrate the Y capacitance, and the basic unit of the flexible metal foil winding is composed of L, N, G three wires, and the structure and the equivalent circuit thereof are shown in fig. 4.
The magnetic core center pillar is added on the basis of the structure of the first embodiment, so that common mode magnetic fluxes generated by the side pillar L, N lines can be seen to be in the same direction when common mode current flows, common mode magnetic fluxes generated by the center pillar L, N lines are offset, differential mode magnetic fluxes generated by the side pillar L, N lines are offset when differential mode current flows, and differential mode magnetic fluxes generated by the center pillar L, N lines are seen to be in the same direction. On the one hand, the differential-mode inductance is decoupled, so that the inductance of the differential-mode inductance can be designed through the length of the air gap of the center pole and the number of turns of the winding, and on the other hand, a path with high magnetic permeability is provided for differential-mode magnetic flux so as to increase the inductance of the differential-mode inductance. Meanwhile, the structural capacitor construction thought of the scheme II is combined, the Y capacitor is constructed by opposite alignment of the differential-mode inductance flexible metal foil winding, the flexible metal foil has several advantages relative to the PCB winding, firstly, the space in the magnetic core can be fully utilized to construct a larger opposite alignment area (larger S), and secondly, more choices (larger epsilon) are provided on the insulating medium material and the thickness thereof r And smaller d), and thirdly, far lower in cost and complexity than the planning and layout of multi-layer boards.
In practical applications of EMI filters, the structure of the EMI filter is determined according to the "impedance mismatch principle", and a common first-order filter structure includes: LC, τ, pi, T. The scheme can be used for forming common mode filters with different structures according to different wiring modes, and wiring ports are shown in the diagram of (L1-L8, N1-N8):
if an LC or τ filter is to be constructed, the common mode current flow is dominant, L1 and N1 are used as input interfaces, L2 and L3 are connected to each other, L4 and L5 are connected to each other, N4 and N6 are connected to each other, L6 and L7 are connected to each other, N5 and N8 are connected to each other, and L8 and N7 are used as output interfaces, and the equivalent circuit structure is shown in fig. 6.
If pi-type filter is to be constructed, the common mode current flow direction is dominant, L5 and N6 are used as input interfaces, L6 is connected with L1, N5 is connected with N1, L2 is connected with L3, N2 is connected with N3, L4 is connected with L7, N4 is connected with N8, and L8 and N7 are used as output interfaces, and the equivalent circuit structure is shown in figure 7.
If a T-type filter is to be constructed, the flow direction of common mode current is dominant, from L1 and N1 as input interfaces, L2 is connected with L5, N2 is connected with N6, L6 is connected with L7, N5 is connected with N8, L8 is connected with L3, N7 is connected with N3, and L4 and N4 are output interfaces, and the equivalent circuit structure at this time is shown in fig. 8.
In general, the embodiment mainly utilizes the flexibility of the flexible material, firstly realizes differential-common mode decoupling through the design of the magnetic core and the winding, improves the effect of magnetic integration, secondly improves the effect of electric integration through the higher utilization rate of the flexible material to the magnetic core space and the diversity of medium material selection, and meanwhile, the cost of the flexible metal foil material is low, so that the cost is convenient to control.
For the EMI filter based on the flexible metal foil material of this embodiment, the main design flow includes: filter structure and parameter design, magnetic core selection, winding design and air gap design, and filter performance verification. The specific method is as follows:
1. filter structure and parameter design
The structure of the EMI filter is determined according to the "impedance mismatch principle", in order to obtain higher insertion loss characteristics, the port corresponding to the high impedance of the noise path of the circuit is preferentially connected to the low-impedance element (filter capacitor) of the filter, the port corresponding to the low impedance of the noise path is preferentially connected to the high-impedance element (filter inductor) of the filter, and generally, there are four common structures of the single-order filter: LC, τ, pi, T. The parameter design of the EMI filter mainly depends on the actual noise condition of the circuit background, the noise condition of the actual circuit is compared with a standard line, the part of the circuit noise exceeding the standard line is the required EMI filter insertion loss requirement, and the required filter inductance and filter capacitance are calculated and selected according to the required insertion loss curve and filter structure.
2. Magnetic core selection
Unlike the AP method used in the traditional magnetic core model selection, the integrated EMI filter provided by the invention mainly considers the required structural capacitance value in the magnetic core model selection, mainly considers the window size of the magnetic core in the model selection, and makes preliminary structural capacitance estimation according to the window size, wherein the estimation basis is as follows:
a) The dielectric constant of the insulating layer material and the thickness of the insulating layer are used to estimate the required flexible metal foil area according to the structural capacitance value of the required design.
b) In the specific calculation, firstly, according to the thickness tau of the basic unit of the flexible metal foil winding, referring to fig. 9, the number of turns of the flexible metal foil around which the magnetic core window can be wound is calculated, and the margin width required by winding the common mode winding around the side column is needed to be considered in the calculation.
c) Secondly, according to the number of turns of the flexible metal foil which is wound and parameters of a middle column of the magnetic core, the length of the flexible metal foil which is required by winding is estimated, according to the height of the magnetic core, the width of the flexible metal foil is given, the length multiplied by the width is calculated, the facing area of the structural capacitor can be obtained, as shown in figure 10, whether the structural capacitance value meets the requirement is calculated reversely according to the obtained estimated parameters, and if not, the model selection is continued until a proper magnetic core is obtained.
3. Winding design and air gap design
Winding the windings according to the differential-common mode decoupling design thought, wherein the differential-common mode magnetic flux is required to be mutually offset or overlapped according to requirements when the differential-common mode current flows, and then determining a wiring mode according to a required filter structure. In winding turns and air gap designs, one considers the differential mode turns limitation determined in core selection, and one considers the inability to saturate the core in the differential mode current flow. A calculation formula of differential mode inductance and a constraint formula of maximum magnetic density:
wherein N is dm For the number of turns of the differential mode winding, u 0 For air permeability, ae is the effective cross-sectional area of the center leg of the core used, l qx For the length of the air gap opened, I pk L is the peak current in the circuit dm And B m Bs is the saturation density of the core for differential mode inductance and maximum density.
4. Filter performance verification
After winding to obtain the integrated EMI filter, actually measuring the insertion loss or checking whether the performance of the filter in the access circuit meets the design requirement, if not, redesigning until the requirement is met.
The present invention is not limited to the above-mentioned preferred embodiments, and any person can obtain other integrated EMI filter structures based on flexible metal foil materials and design methods thereof in various forms under the teachings of the present invention, and all equivalent changes and modifications made according to the scope of the present invention should be covered by the present invention.
Claims (6)
1. An integrated EMI filter structure based on flexible metal foil material, characterized by: adopting an EE type magnetic core with a three-winding column structure, winding a side column by using a conventional winding to form a common-mode winding, winding a middle column by using a flexible metal foil to form a differential-mode winding, and integrating a Y capacitor; the basic unit of the flexible metal foil winding consists of L, N, G three wires, wherein the L wire, the GND wire and the N wire are insulated by a dielectric layer;
the joint of the first winding of the common mode winding comprises L1, L2, N1 and N2, and the joint of the second winding comprises L3, L4, N3 and N4; the joint of the third winding of the common mode winding comprises L5, L6, N5 and N6, and the joint of the fourth winding comprises L7, L8, N7 and N8; the filters with different structures are constructed and obtained through different connection modes of the connectors;
when the magnetic core is selected, the window size of the magnetic core is considered, and preliminary structural capacitance estimation is made according to the window size, wherein the estimation basis is as follows:
(1) According to the structural capacitance value of the required design, the dielectric constant of the insulating layer material and the thickness of the insulating layer are used, and the area of the required flexible metal foil is estimated;
(2) Firstly, calculating the number of turns of flexible metal foil which can be wound down by a magnetic core window according to the thickness tau of a basic unit of the flexible metal foil winding, and considering the allowance width required by winding a common mode winding by a side column during calculation;
(3) Estimating the length of the flexible metal foil required by winding according to the number of turns of the flexible metal foil to be wound and parameters of a central column of the magnetic core, calculating the length multiplied by the width according to the height of the magnetic core and given width of the flexible metal foil to obtain the facing area of the structural capacitor, and reversely calculating whether the structural capacitance value meets the requirement according to the obtained estimated parameters, if not, continuing to select the shape until a proper magnetic core is obtained;
in winding turns and air gap designs, on the one hand the differential mode turns limitation determined in the core selection is considered, and on the other hand the inability to saturate the core in the incoming differential mode current is considered; a calculation formula of differential mode inductance and a constraint formula of maximum magnetic density:
wherein N is dm Turns, mu, of differential mode winding 0 For air permeability, ae is the effective cross-sectional area of the center leg of the core used, l qx For the length of the air gap opened, I pk L is the peak current in the circuit dm And B max For differential mode inductance and maximum magnetic density, bs is the saturation magnetic of the coreAnd (5) sealing.
2. The integrated EMI filter structure based on flexible metal foil material of claim 1, wherein: common mode magnetic fluxes generated by the side column L, N lines are in the same direction when common mode current flows, common mode magnetic fluxes generated by the middle column L, N lines are offset, differential mode magnetic fluxes generated by the side column L, N lines are offset when differential mode current flows, and differential mode magnetic fluxes generated by the middle column L, N lines are in the same direction.
3. The integrated EMI filter structure based on flexible metal foil material of claim 1, wherein: in the practical application of the EMI filter, the structure of the EMI filter is determined according to the principle of impedance mismatch.
4. The integrated EMI filter structure based on flexible metal foil material of claim 1, wherein: the LC or tau-type filter is obtained by taking the flow direction of common mode current as a main, taking L1 and N1 as input interfaces, connecting L2 with L3, N2 with N3, connecting L4 with L5, N4 with N6, connecting L6 with L7, connecting N5 with N8, and taking L8 and N7 as output interfaces.
5. The integrated EMI filter structure based on flexible metal foil material of claim 1, wherein: the common mode current flow is used as the leading, L5 and N6 are used as input interfaces, L6 is connected with L1, N5 is connected with N1, L2 is connected with L3, N2 is connected with N3, L4 is connected with L7, N4 is connected with N8, and L8 and N7 are used as output interfaces, so that the pi-type filter is obtained.
6. The integrated EMI filter structure based on flexible metal foil material of claim 1, wherein: the flow direction of common mode current is taken as a leading, L1 and N1 are taken as input interfaces, L2 is connected with L5, N2 is connected with N6, L6 is connected with L7, N5 is connected with N8, L8 is connected with L3, N7 is connected with N3, and L4 and N4 are taken as output interfaces, so that the T-shaped filter is obtained.
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