Inductor Geometry With Improved Energy Density

The “constant-flux” concept is leveraged to achieve high magnetic-energy density, leading to inductor geometries with height significantly lower than that of conventional products. Techniques to shape the core and to distribute the winding turns to shape a desirable field profile are described for the two basic classes of magnetic geometries: those with the winding enclosed by the core and those with the core enclosed by the winding. A relatively constant flux distribution is advantageous not only from the density standpoint, but also from the thermal standpoint via the reduction of hot spots, and from the reliability standpoint via the suppression of flux crowding. In this journal paper on a constant-flux inductor (CFI) with enclosed winding, the foci are operating principle, dc analysis, and basic design procedure. Prototype cores and windings were routed from powder-iron disks and copper sheets, respectively. The design of CFI was validated by the assembled inductor prototype.