# US 10,121,582 B2 · Integrated inductor

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- Number: US 10,121,582 B2
- Document ID: US10121582B2
- Status: Granted
- Kind: B2
- Application number: 15/103,421
- Filed: 2014-10-31
- Published: 2016-10-27
- Granted: 2018-11-06
- Earliest claimed: 2013-12-12
- Assignees: Eaton Intelligent Power Limited
- Applicants: Eaton Corproation
- Inventors: David Zheng; Wen Wang; Xizheng Liao; Denis Liu
- Web page: https://patentgrep.com/patent/US10121582B2

## CPC

- H01F 27/24: Magnetic cores
- H01F 3/10: Composite arrangements of magnetic circuits
- H01F 3/14: Constrictions; Gaps, e.g. air-gaps (in magnetic shunt paths H01F3/12)
- H01F 27/2823: {Wires (H01F27/2866 takes precedence)}
- H01F 37/00: Fixed inductances not covered by group H01F17/00
- H01F 2003/106: {Magnetic circuits using combinations of different magnetic materials}
- H01F: MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES

## Abstract

An integrated inductor comprises a first winding (C1) and a second winding (C2); a first internal magnetic core in the first winding (C1) and a second internal magnetic core in the second winding (C2); and at least one external magnetic core (M) outside the first winding (C1) and the second winding (C2), used for being connected to end portions of the first and second internal magnetic cores to form a magnetic path, the external magnetic core (M) being formed by multiple sub-magnetic cores joint with each other; the magnetic conductivity of at least one sub-magnetic core of the multiple sub-magnetic cores is greater than the magnetic conductivity of other sub-magnetic cores, and the at least one sub-magnetic core at least covers a part of end faces of the first internal magnetic core and the second internal magnetic core. The integrated inductor can alleviate the phenomenon of flux leakage, and can reduce costs of the magnetic cores.

## Claims

### Claim 1

An integrated inductor, comprising:
a first winding and a second winding;
a first internal core located inside the first winding and a second internal core located inside the second winding; and
at least one external core comprising a plurality of sub-cores and located outside the first winding and the second winding, the at least one external core, the first internal core and the second internal core forming a magnetic circuit,
wherein at least one sub-core of the plurality of sub-cores has a higher magnetic permeability than at least one other sub-core of the plurality of sub-cores, wherein the at least one sub-core at least partially overlaps end faces of respective ones of the first internal core and the second internal core, and wherein first and second ones of the at least one other sub-core of the plurality of sub-cores are disposed on respective first and second lateral sides of the at least one sub-core which has a higher magnetic permeability.

### Claim 2 (depends on 1)

The integrated inductor of claim 1, wherein the at least one sub-core which has a higher magnetic permeability overlaps the end faces of the first internal core and the second internal core to midpoints thereof.

### Claim 3 (depends on 1)

The integrated inductor of claim 1, wherein the at least one sub-core which has a higher magnetic permeability completely overlaps the end faces of the first internal core and the second internal core.

### Claim 4 (depends on 1)

The integrated inductor of claim 1, wherein the external core is flat-shaped.

### Claim 5 (depends on 1)

The integrated inductor of claim 1, wherein third and fourth ones of the at least one other sub-core of the plurality of sub-cores are disposed on respective first and second ends of the at least one sub-core which has a higher magnetic permeability than other sub-cores.

### Claim 6 (depends on 1)

The integrated inductor of claim 1, wherein ends of the external core are arc-shaped.

### Claim 7 (depends on 1)

The integrated inductor of claim 1, wherein some of the plurality of sub-cores have arc-shaped edges, and the sub-cores with arc-shaped edges are located at ends of the external core.

### Claim 8

An apparatus, comprising:
a magnetic core comprising first and second substantially parallel core portions and third and fourth core portions at least partially overlapping respective first and second ends of the first and second core portions, wherein the third and fourth core portions comprise respective first and second pluralities of discrete magnetic material segments including at least one segment having a higher magnetic permeability than other ones of the segments, wherein the at least one segment having a higher magnetic permeability comprises a first elongate magnetic material bar and wherein the segments further comprise second and third elongate magnetic material bars disposed on respective first and second lateral sides of the first elongate magnetic material bar and having a magnetic permeability less than that of the first elongate magnetic material bar; and
first and second windings on respective ones of the first and second core portions.

### Claim 9 (depends on 8)

The apparatus of claim 8, wherein the third and fourth core portions comprise arc-shaped magnetic material regions disposed at ends of the first, second and third elongate magnetic material bars.

### Claim 10 (depends on 8)

The apparatus claim 8, wherein the first and second windings are electrically connected.