隨著電動車市場的發展，各類電源轉換器追求高功率密度，而電感器在轉換器中占據了大部分空間。傳統方法是通過提高切換頻率來減小電感體積，但這也導致了能量損耗增加和電磁干擾（EMI）問題。本研究基於傳統的EE形電感器，對其磁路進行最佳化，提出了一種三維電感器的設計構型，以解決傳統電感器佔板面積過大的問題，並彌補過去傳統電感器在磁路最佳化方面的不足。
本研究通過改變氣隙的形狀、設計頂面以及引入倒角和圓角來改進電感器的性能，並提出了一套完整的設計流程和計算公式。研究方向不僅著重於減小體積，還包括提升電感值和飽和電流。結合田口實驗法，本研究找出了關鍵影響參數，並利用有限元素分析（Finite Element Analysis, FEA）進行驗證。最後，研究使用磁性材料進行選擇性雷射熔融（Selective Laser Melting, SLM）金屬積層列印來製作實物，並將其與有限元素分析結果進行比對。

With the development of the electric vehicle market, various power converters are pursuing high power density, with inductors occupying a significant portion of the space within these converters. The traditional approach to reducing the volume of inductors involves increasing the switching frequency, but this also leads to increased energy losses and electromagnetic interference (EMI) issues. This study optimizes the magnetic circuit of traditional EE-shaped inductors and proposes a three-dimensional inductor design configuration to address the excessive board space occupied by conventional inductors and to compensate for the shortcomings in magnetic circuit optimization of previous two-dimensional inductors.
This research improves the performance of inductors by altering the shape of the air gap, designing the top surface, and introducing chamfers and fillets. A comprehensive design process and calculation formulas are also presented. The research focus not only aims to reduce the volume but also to enhance the inductance value and saturation current. By combining the Taguchi method, key influencing parameters were identified, and finite element analysis (FEA) was employed for verification. Finally, the study utilized selective laser melting (SLM) metal additive manufacturing with magnetic materials to fabricate the actual inductor, and the results were compared with the finite element analysis outcomes.

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