Inductor and method for producing the same
The disclosure provides an inductor and a method for producing the same. The inductor includes a first core made of a first magnetic material; at least two windings, configured to be twisted with each other and embedded within the first core, each winding having a pair of terminals extending out of the first core.
1. An inductor, comprising:
a first core made of a first magnetic material;
at least two windings, configured to be twisted with each other and embedded within the first core, each winding having a pair of terminals extending out of the first core; and
a second core enclosing the first core, wherein the second core is made of a second magnetic material having a higher magnetic permeability than that of the first magnetic material, and the terminals of the windings extend out of the second core.
2. The inductor according to claim 1 , wherein
the at least two windings are made of copper or aluminum,
the first magnetic material is a mouldable soft magnetic material,
the second magnetic material is a mouldable soft magnetic material or selected from an iron powder material, ferrites or nanocrystalline materials.
3. The inductor according to claim 1 , wherein
the at least two windings are separated from each other within the first core by a predetermined distance.
4. The inductor according to claim 1 , wherein
the number of twists of each winding is an integer multiple of the number of turns of the winding.
5. The inductor according to claim 1 , wherein
the at least two windings comprise two windings, three windings or more.
6. The inductor according to claim 1 , wherein
the inductor is provided with a cooling passage therein through which coolant flows.
7. The inductor according to claim 1 , wherein
two terminals for the same winding are located close to each other, or are spaced apart from each other in a circumferential direction, e.g., located at a quarter or a half of a turn of the winding.
8. The inductor according to claim 1 , wherein the pairs of terminals of different windings are equally spaced in a circumferential direction.
9. The inductor according to claim 1 , wherein
the terminals are located on any surface of the inductor.
10. The inductor according to claim 1 , wherein
the windings have a ring, oval, rectangular, triangle shape or their combination in a plan view.
11. The inductor according to claim 1 , wherein
the inductor has a cylinder, oval cylinder, tube, triangular prism, sphere, toroidal or donut shape.
12. The inductor according to claim 1 , wherein
the inductor is applicable to a LCL-filter, a sine filter, dU/dt filters, a converter, a transformer, or an EMI filter.
13. A method for producing the inductor according to claim 1 , comprising the following steps:
1) Providing a package of the at least two windings twisted and separated from each other; and
2) forming the first core from the first magnetic material over the at least two windings.
14. A method for producing the inductor according to claim 1 , comprising the following steps:
1) Providing a package of the at least two windings twisted and separated from each other;
2) forming the first core from the first magnetic material over the at least two windings; and
3) forming the second core from the second magnetic material over the first core.
15. The method according to claim 13 , further comprising:
forming terminals for each of the windings before the step 2) of forming the first core.
16. The method according to claim 13 , further comprising:
forming cooling passage for at least one of the windings.
17. The method according to claim 13 , wherein at least one of the steps is performed by a 3D-printing technique, a casting technique or an assembling technique.