Power supply module and winding assembly

Abstract

In one embodiment, the power supply module comprises a first printed circuit board, a second printed circuit board, a mutual inductor magnetic core and at least one conductive column. The mutual inductance inductor magnetic core is clamped between the first printed circuit board and the second printed circuit board, and the mutual inductance inductor magnetic core comprises at least one open groove which enables the first printed circuit board to be exposed out of the second printed circuit board. The at least one conductive pillar extends through the at least one slot and electrically connects the first printed circuit board to the second printed circuit board.

Description

Technical Field

[0001] The technical field of the present disclosure relates to a power supply module, and in particular, to a power supply module using a multi-mutual inductance inductor. Background Art

[0002] Typical power supply modules face significant challenges in optimizing performance, especially in high-performance computing systems. When supporting large current application-specific integrated circuits, server load power supply terminals, and telecommunications applications, etc., the placement of power supply components (such as inductors) is crucial. Traditional methods usually cannot effectively solve the space and thermal limitations associated with these types of applications. Therefore, while achieving optimal power supply, minimizing the height of the power supply module, in addition to increasing the power density of the power supply module, also ensures the reliability and efficiency of the power supply module. Summary of the Invention

[0003] In one or more embodiments of the present disclosure, the power supply module includes a first printed circuit board, a second printed circuit board, a mutual inductance inductor core, and at least one conductive post. The mutual inductance inductor core is sandwiched between the first printed circuit board and the second printed circuit board, and the mutual inductance inductor core includes at least one slot to expose the first printed circuit board to the second printed circuit board. The conductive post extends through the slot and electrically connects the first printed circuit board to the second printed circuit board.

[0004] In one or more embodiments of the present disclosure, at least one slot includes a plurality of slots. At least one conductive post includes a plurality of pairs of primary and secondary winding posts. Each pair of the plurality of pairs of primary and secondary winding posts is disposed in a different one of the plurality of slots.

[0005] In one or more embodiments of the present disclosure, the power supply module further includes a tab extending into one of the plurality of slots. The tab is disposed on a pair of the plurality of pairs of primary and secondary winding posts, and is configured to transform the leakage inductance between a pair of the plurality of pairs of primary and secondary winding posts.

[0006] In one or more embodiments of the present disclosure, the power supply module further includes a plurality of connection posts and a plurality of conductive traces. The connection posts are located outside the mutual inductance inductor core and extend between the first printed circuit board and the second printed circuit board. The conductive traces are formed on the first printed circuit board and the second printed circuit board, and electrically connect different primary and secondary winding posts together in a winding arrangement through the connection posts.

[0007] In one or more embodiments of the present disclosure, the winding arrangement is a series winding arrangement.

[0008] In one or more embodiments of the present disclosure, the power supply module further includes a toroidal core wound around one of the plurality of connection posts.

[0009] In one or more embodiments of the present disclosure, a mutual inductance inductor core includes a first side, a second side, and a central portion. The central portion is sandwiched between the first side and the second side. At least one slot includes a plurality of slots formed between the first side and the central portion and / or between the second side and the central portion.

[0010] In one or more embodiments of the present disclosure, the central portion includes a plurality of crossbars extending toward the first side and the second side, and the crossbars define a plurality of slots.

[0011] In one or more embodiments of the present disclosure, the central portion includes at least one tab between the crossbars and extending into one of the plurality of slots.

[0012] In one or more embodiments of the present disclosure, the conductive posts include primary and secondary winding posts, each disposed on a different side of the tab.

[0013] In one or more embodiments of the present disclosure, a first gap is formed between the first side and the central portion, a second gap is formed between the second side and the central portion, and the first gap and the second gap have a predetermined spacing.

[0014] In one or more embodiments of the present disclosure, the first gap and the second gap are filled with a gap spacer.

[0015] In one or more embodiments of the present disclosure, the predetermined spacing varies along the length of the mutual inductance inductor core.

[0016] In one or more embodiments of the present disclosure, at least one slot includes a plurality of slots. At least one conductive post includes a plurality of primary winding posts, each disposed in one of the plurality of slots and forming a single-turn primary winding for the mutual inductance inductor core. The power supply module further includes a controller configured to perform pulse width modulation phasing of the primary winding posts based on the configuration of the mutual inductance inductor core.

[0017] In one or more embodiments of the present disclosure, the winding assembly includes a first printed circuit board, a second printed circuit board, at least one mutual inductance inductor core, and a plurality of pairs of conductive posts. The mutual inductance inductor core is sandwiched between the first printed circuit board and the second printed circuit board. Each mutual inductance inductor core includes a first side, a second side, and a central portion. The central portion is sandwiched between the first side and the second side. The central portion includes a plurality of crossbars extending toward the first side and the second side, and the crossbars define a plurality of slots. The conductive posts extend through the slots to electrically connect the first printed circuit board to the second printed circuit board. Each pair of the plurality of pairs of conductive posts forms a primary and a secondary winding for the mutual inductance inductor core.

[0018] In one or more embodiments of the present disclosure, the winding assembly further includes a tab that extends into one of the plurality of slots. The tab is disposed between a pair of the plurality of conductive posts and is configured to transform the leakage inductance between one of the primary and secondary windings.

[0019] In one or more embodiments of the present disclosure, the winding assembly further includes a plurality of connection posts and a plurality of conductive traces. The connection posts are located outside the core of the mutual inductance inductor and extend between the first printed circuit board and the second printed circuit board. The conductive traces are formed on the first printed circuit board and the second printed circuit board and are electrically connected to the primary and secondary windings in a winding arrangement through the connection posts.

[0020] In one or more embodiments of the present disclosure, the winding arrangement is a series winding arrangement.

[0021] In one or more embodiments of the present disclosure, the winding assembly further includes a plurality of toroidal cores, each winding around one of the plurality of connection posts.

[0022] In one or more embodiments of the present disclosure, the power supply module includes a first printed circuit board, a second printed circuit board, a core of a mutual inductance inductor, a plurality of pairs of conductive posts, a plurality of connection posts, a plurality of conductive traces, and a controller. The core of the mutual inductance inductor is sandwiched between the first printed circuit board and the second printed circuit board and includes a first side, a second side, and a central portion. The central portion is sandwiched between the first side and the second side, and the central portion includes a plurality of crossbars that extend toward the first side and the second side, and the crossbars define a plurality of slots. The plurality of pairs of conductive posts extend through the plurality of slots and electrically connect the first printed circuit board to the second printed circuit board. Each pair of the plurality of pairs of conductive posts forms a primary and a secondary winding for the core of the mutual inductance inductor. The connection posts are located outside the core of the mutual inductance inductor and extend between the first printed circuit board and the second printed circuit board. The conductive traces are formed on the first printed circuit board and the second printed circuit board and are electrically connected to the conductive posts in a winding arrangement through the connection posts. The controller is configured to perform pulse width modulation phase sequencing of the primary winding connected to each pair of the plurality of pairs of conductive posts. Description of the Drawings

[0023] These and other features, aspects, and advantages of the present disclosure will become better understood when the following embodiments are read with reference to the accompanying drawings. Wherein like reference numerals represent like parts in all the drawings.

[0024] Figure 1A Is a top view of a core of a mutual inductance inductor shown in an exemplary embodiment.

[0025] Figure 1B Is shown in an exemplary embodiment Figure 1A of the end view of the core of the mutual inductance inductor.

[0026] Figures 2A to 2GTop view of various mutual inductance inductor cores shown in an exemplary embodiment.

[0027] Figure 3A Top view of the winding assembly of a mutual inductance inductor core shown in an exemplary embodiment using Figure 1A and Figure 1B .

[0028] Figure 3B Side view of the winding assembly shown Figure 3A .

[0029] Figure 4 Top view of the winding assembly of two mutual inductance inductor cores shown in an exemplary embodiment using Figure 1A and Figure 1B .

[0030] Figure 5A Top view of the winding assembly of a mutual inductance inductor core shown in another exemplary embodiment using Figure 1A and Figure 1B .

[0031] Figure 5B Side view of the winding assembly shown in an exemplary embodiment of Figure 5A .

[0032] Figure 5C End view of the winding assembly shown in an exemplary embodiment of Figure 5A .

[0033] Figure 6 Top view of the winding assembly of a mutual inductance inductor core shown in another exemplary embodiment using Figure 1A and Figure 1B .

[0034] Figure 7 End view of the power supply module of a mutual inductance inductor core shown in an exemplary embodiment using Figure 1A and Figure 1B .

[0035] Figure 8 Top view of the winding assembly of two mutual inductance inductor cores shown in an exemplary embodiment using Figure 1A and Figure 1B .

[0036] Figure 9 Partial circuit diagram of the electrical configuration corresponding to the winding assembly shown in an exemplary embodiment of Figure 8 .

[0037] Wherein, the reference numerals are explained as follows:

[0038] 102, 202, 204, 206, 208, 210, 212, 214: Mutual inductance inductor cores

[0039] 104, 218: Central part

[0040] 106: First side part

[0041] 108: Second side part

[0042] 110: First gap

[0043] 112: Second gap

[0044] 114: Length

[0045] 116: Width

[0046] 118: Height

[0047] 120, 122, 124, 126: Cross bars

[0048] 128, 130, 132, 134, 136, 138, 428, 430, 432, 434, 436, 438, 440, 442, 444, 446, 448, 450, 828, 830, 832, 834, 836, 838, 840, 842, 844, 846, 848, 850: Slots

[0049] 216: Side part

[0050] 302, 402, 502, 602, 802: Winding assemblies

[0051] 304, 306, 308, 310, 312, 314, 404, 406, 408, 410, 412, 414, 416, 418, 420, 422, 424, 426, 804, 806, 808, 810, 812, 814, 816, 818, 820, 822, 824, 826: Primary winding posts

[0052] 316, 318, 320, 322, 324, 326, 452, 454, 456, 458, 460, 462, 464, 466, 468, 470, 472, 474, 852, 854, 856, 858, 860, 862, 864, 866, 868, 870, 872, 874: Secondary winding posts

[0053] 328, 476, 876: First printed circuit board trace

[0054] 330, 478, 878: Second printed circuit board trace

[0055] 332: First printed circuit board

[0056] 334: Second printed circuit board

[0057] 336: First surface

[0058] 338: Second surface

[0059] 340: Third surface

[0060] 342: Fourth surface

[0061] 344, 480, 880: Connecting post

[0062] 504, 506, 508, 510, 512: Toroidal core

[0063] 604, 606, 608, 610, 612, 614: Tab

[0064] 702: Power supply module

[0065] 704, 706: Power integrated circuit

[0066] 902: Circuit diagram

[0067] SWN1, SWN1’, SWN2, SWN2’, SWN3, SWN3’, SWN4, SWN4’, SWN5, SWN5’, SWN6, SWN6’, GND: Switching node Detailed implementation mode

[0068] Many terms will be cited in the following description and claims, and these terms should be defined as having the following meanings.

[0069] The singular forms "a" and "the" include plural references unless the context clearly indicates otherwise.

[0070] "Optional" or "optionally" means that the subsequent described event or situation may or may not occur, and this description includes the situation where the event occurs or the situation where the event does not occur.

[0071] The approximate terms used throughout this specification and claims may be used to modify any quantitatively represented variation that is allowed without causing a change in its related basic function. Therefore, a numerical value modified by one or more terms, such as "about", "approximately", and "substantially", is not limited to the specified exact value. In at least some embodiments, the approximate term may correspond to the precision of the instrument used to measure the numerical value. Herein and throughout the specification and claims, range limitations may be combined and / or interchanged unless the context or the words indicate otherwise, and such ranges are recognized and include all the sub-ranges contained therein.

[0072] The present disclosure describes a mutual inductance inductor core and a power module using the mutual inductance inductor core. In various embodiments, the mutual inductance inductor core described herein can be designed for single-phase or multi-phase power modules. The multi-phase mutual inductance inductor core can be implemented using one or more ferrite cores, which can be combined into a core assembly according to the application. For example, two six-phase mutual inductance inductor cores can be combined in a power module to implement a twelve-phase mutual inductance inductor core voltage regulator. The mutual inductance inductor core combines the properties of a transformer and a coupled inductor within the same core and winding assembly, thereby optimizing power transmission in the power module. Using a custom core and winding assembly with, for example, a zinc magnesium ferrite core, the mutual inductance inductor core described herein utilizes primary and secondary windings formed by conductive posts extending between two printed circuit boards, with the mutual inductance inductor core sandwiched therebetween. Using conductive posts between two printed circuit boards can reduce losses, optimize efficiency, improve transient response, and address the space and thermal limitations of high-performance point-of-load applications (e.g., high-performance computing applications). The conductive posts can also be used for power conduction or grounding between the two printed circuit boards, which also improves the conduction loss between the two printed circuit boards and minimizes the height of the power module.

[0073] Figure 1A FIG. 1B is a top view of a mutual inductance inductor core 102 shown in an exemplary embodiment. FIG. 1B is an end view of the mutual inductance inductor core 102 shown in an exemplary embodiment. In this embodiment, the mutual inductance inductor core 102 includes a central portion 104 sandwiched between a first side portion 106 and a second side portion 108. A first gap 110 is formed between the first side portion 106 and the central portion 104, and a second gap 112 is formed between the second side portion 108 and the central portion 104. In this embodiment, the mutual inductance inductor core 102 has a length 114, a width 116, and a height 118 (see Figure 1B ). The specific relationship among the length 114, width 116, and height 118 of the mutual inductance inductor core 102, and other mutual inductance inductor cores described herein, is presented as one configuration for discussion purposes only. And the mutual inductance inductor core 102 and other mutual inductance inductor cores described herein can be implemented in different desired configurations. The mutual inductance inductor core 102 can be formed of various types of ferrite materials, such as zinc magnesium.

[0074] In the present embodiment, the central portion 104 includes a plurality of cross bars 120, 122, 124, 126 extending in the direction of the width 116 of the mutual inductor magnetic core 102. The cross bars 120, 122, 124, 126 define a plurality of slots 128, 130, 132, 134, 136, 138, which are further defined between the central portion 104 of the mutual inductor magnetic core 102 and the first and second side portions 106, 108. In the present embodiment, the dimensions of the slots 128, 130, 132, 134, 136, 138 are used to provide space for primary and secondary single-turn windings (not shown in the figure), and the primary and secondary single-turn windings are formed by conductive posts extending between two printed circuit boards (not shown in the figure).

[0075] In some embodiments, the first and second gaps 110, 112 formed between the central portion 104 and the first and second side portions 106, 108 have a predetermined spacing. In some embodiments, the first and second gaps 110, 112 are filled with gap spacers (not shown in the figure), and the gap spacers are used to prevent the mutual inductor magnetic core 102 from saturating and improve the stability of the inductance value required when the mutual inductor magnetic core 102 is used in a power module. The predetermined spacing generated by the first and second gaps 110, 112 is also used to linearize the hysteresis curve of the mutual inductor magnetic core 102 by reducing the magnetic permeability of the mutual inductor magnetic core 102. In some embodiments, the predetermined spacing of the first and second gaps 110, 112 is the same spacing. In other embodiments, the first and second gaps 110, 112 utilize different predetermined spacings. In some embodiments, the predetermined spacing of the first and second gaps 110, 112 is consistent along the length 114 of the mutual inductor magnetic core 102. In other embodiments, the predetermined spacing of the first and second gaps 110, 112 varies along the length 114 of the mutual inductor magnetic core 102.

[0076] Figures 2A to 2GA top view of various mutual inductance inductor cores 202, 204, 206, 208, 210, 212, 214 that can be used to scale a mutual inductance inductor core power module as shown in an exemplary embodiment. The mutual inductance inductor cores 202, 204, 206, 208, 210, 212, 214 can be formed of various types of ferromagnetic materials, such as zinc magnesium. In addition, the mutual inductance inductor cores 202, 204, 206, 208, 210, 212, 214 may include elements or structures similar to the previously described mutual inductance inductor core 102, such as side portions 216 and a central portion 218. The side portions 216 and the central portion 218 utilize connection posts (not shown in the figure) to achieve single-turn primary and secondary windings. In this embodiment, the mutual inductance inductor core 202 does not include the central portion 218, and the mutual inductance inductor core 214 is formed by two adjacent segments of the mutual inductance inductor core 212. The mutual inductance inductor core 212 may be substantially similar to Figure 1A the depicted mutual inductance inductor core 102.

[0077] In this embodiment, the mutual inductance inductor cores 202, 204, 206, 208, 210, 212, 214 are constructed to respectively implement single-phase, two-phase, three-phase, four-phase, five-phase, six-phase, and twelve-phase power modules.

[0078] Figure 3A A top view of a winding assembly 302 that utilizes the mutual inductance inductor core 102 as shown in an exemplary embodiment. Figure 3B An end view of the winding assembly 302 is shown. In this embodiment, the winding assembly 302 includes six primary winding posts 304, 306, 308, 310, 312, 314 respectively disposed in slots 128, 130, 132, 134, 136, 138 to form the primary winding of the winding assembly 302. And six secondary winding posts 316, 318, 320, 322, 324, 326 are also respectively disposed in slots 128, 130, 132, 134, 136, 138 to form the secondary winding of the winding assembly 302.

[0079] In Figure 3A , the secondary winding posts 316, 318, 320, 322, 324, 326 are at least partially wired in series respectively by first and second printed circuit board traces 328, 330 formed in a first printed circuit board 332 and a second printed circuit board 334. Please refer to Figure 3B, the first printed circuit board 332 includes a first surface 336 and an opposite second surface 338, and the second printed circuit board 334 includes a third surface 340 and an opposite fourth surface 342. The first printed circuit board trace 328 is formed in the second surface 338 of the first printed circuit board 332, and the second printed circuit board trace 330 is formed in the third surface 340 of the second printed circuit board 334. In this embodiment, the mutual inductance inductor core 102 is disposed between the first and second printed circuit boards 332, 334, and the primary winding posts 304, 306, 308, 310, 312, 314 and the secondary winding posts 316, 318, 320, 322, 324, 326 extend between the first and second printed circuit boards 332, 334. Figure 3A and Figure 3B Also shown is a connection post 344 disposed outside the mutual inductance inductor core 102. The connection post 344 is used to connect the first and second printed circuit board traces 328, 330 and / or to electrically couple the first and second printed circuit boards 332, 334 together. For example, the connection post 344 can be used to electrically couple the power supply and ground circuits in the first and second printed circuit boards 332, 334 together. The primary winding posts 304, 306, 308, 310, 312, 314 and the secondary winding posts 316, 318, 320, 322, 324, 326 and the connection post 344 are conductive structures electrically coupled to the first and second printed circuit boards 332, 334. For example, the posts described herein can be welded or otherwise electrically connected to the first and second printed circuit boards 332, 334. For example, the posts may be welded into blind holes formed in the first and second printed circuit boards 332, 334 and other printed circuit boards described herein. For example, the blind holes can extend through one or more copper layers of the first and second printed circuit boards 332, 334 and other printed circuit boards described herein. In some embodiments, the posts described herein extend completely through the first and second printed circuit boards 332, 334 and other printed circuit boards described herein.

[0080] Figure 4A top view of a winding assembly 402 utilizing two mutually inductive inductor cores 102 as shown in an exemplary embodiment. In this embodiment, the winding assembly 402 includes twelve primary winding posts 404, 406, 408, 410, 412, 414, 416, 418, 420, 422, 424, 426 respectively disposed in slots 428, 430, 432, 434, 436, 438, 440, 442, 444, 446, 448, 450 to form the primary winding for the winding assembly 402. The winding assembly 402 further includes twelve secondary winding posts 452, 454, 456, 458, 460, 462, 464, 466, 468, 470, 472, 474 respectively disposed in slots 428, 430, 432, 434, 436, 438, 440, 442, 444, 446, 448, 450 to form the secondary winding for the winding assembly 402.

[0081] In Figure 4 it, the secondary winding posts 452, 454, 456, 458, 460, 462, 464, 466, 468, 470, 472, 474 are respectively wired in series by first and second printed circuit board traces 476, 478 formed in a first printed circuit board (not shown) and a second printed circuit board (not shown). In this embodiment, the mutually inductive inductor core 102 is disposed between the first and second printed circuit boards (not shown), and the primary winding posts 404, 406, 408, 410, 412, 414, 416, 418, 420, 422, 424, 426 and the secondary winding posts 452, 454, 456, 458, 460, 462, 464, 466, 468, 470, 472, 474 extend between the first and second printed circuit boards (not shown). Figure 4 Also shown is a connection post 480 disposed outside the mutually inductive inductor core 102, the connection post 480 being used to connect the first and second printed circuit board traces 476, 478, and / or to electrically couple the first and second printed circuit boards (not shown) together. For example, the connection post 480 can be used to electrically couple the power supply and ground circuits in the first and second printed circuit boards (not shown) together. Figure 4 The structure of Figure 3A and Figure 3B is thus similar to the structure described in

[0082] Figure 5A A top view of a winding assembly 502 utilizing a mutually inductive inductor core 102 as shown in another exemplary embodiment. Figure 5B And Figure 5C respectively show a side view and an end view of the winding assembly 502. The winding assembly 502 is similar to the winding assembly 302 (seeFigure 3A and Figure 3B ), wherein the winding assembly 502 includes toroidal cores 504, 506, 508, 510, 512 wound around the connection posts 344 to increase the inductance of the secondary winding formed by the series connection of the secondary winding posts 316, 318, 320, 322, 324, 326 and the first printed circuit board trace 328 and the second printed circuit board trace 330.

[0083] Figure 6 FIG. is a top view of a winding assembly 602 utilizing the mutual inductance inductor core 102 shown in another exemplary embodiment. The winding assembly 602 is similar to the winding assembly 502 (see Figure 5A 、 Figure 5B and Figure 5C ), wherein the central portion 104 includes tabs 604, 606, 608, 610, 612, 614 extending into slots 128, 130, 132, 134, 136, 138 respectively towards the first and second side portions 106, 108 of the mutual inductance inductor core 102. The tabs 604, 606, 608, 610, 612, 614 can be sized as needed to change the leakage inductance between the primary and secondary windings of the winding assembly 602 formed by the primary winding posts 304, 306, 308, 310, 312, 314 and the secondary winding posts 316, 318, 320, 322, 324, 326. Adjusting the leakage inductance ensures a high frequency bandwidth, minimizes delay, and improves the transient response of the power module utilizing the winding assembly 602.

[0084] Figure 7 FIG. is an end view of a power supply module 702 utilizing the mutual inductance inductor core 102 shown in an exemplary embodiment. Figure 7 The view of Figure 3BThe winding assembly 302 depicted in the view. The power supply module 702 includes various electronic components for implementing a voltage regulator including a plurality of power integrated circuits 704, 706. In the present embodiment, the power integrated circuits 704, 706 form switching nodes and are located on the first surface 336 of the first printed circuit board 332. The power integrated circuits 704, 706 can be directly located above the primary winding posts 304, 306, 308, 310, 312, 314 to minimize parasitic losses and reduce losses of direct current and alternating current, thereby improving the performance of the power supply module 702. For example, the power integrated circuits 704, 706 can include switching nodes electrically coupled to the primary winding posts 304, 306, 308, 310, 312, 314 and associated regulating circuits to implement a six-phase mutual inductance voltage regulator. In some embodiments, the second printed circuit board 334 includes capacitors (e.g., disposed on the fourth surface 342, not shown in the figure) that serve as part of the output voltage nodes of the power supply module 702.

[0085] Figure 8 A top view of a winding assembly 802 utilizing two mutual inductance inductor cores 102 in an exemplary embodiment is shown. In the present embodiment, the winding assembly 802 includes twelve primary winding posts 804, 806, 808, 810, 812, 814, 816, 818, 820, 822, 824, 826 respectively disposed in slots 828, 830, 832, 834, 836, 838, 840, 842, 844, 846, 848, 850 to form the primary winding for the winding assembly 802. The winding assembly 802 further includes twelve secondary winding posts 852, 854, 856, 858, 860, 862, 864, 866, 868, 870, 872, 874 respectively disposed in slots 828, 830, 832, 834, 836, 838, 840, 842, 844, 846, 848, 850 to form the secondary winding for the winding assembly 802.

[0086] In Figure 8Among them, the secondary winding posts 852, 854, 856, 858, 860, 862, 864, 866, 868, 870, 872, 874 are wired in series by the first and second printed circuit board traces 876, 878 formed in a first printed circuit board (not shown) and a second printed circuit board (not shown). In this embodiment, the mutual inductance inductor core 102 is disposed between the first and second printed circuit boards (not shown), and the primary winding posts 804, 806, 808, 810, 812, 814, 816, 818, 820, 822, 824, 826 and the secondary winding posts 852, 854, 856, 858, 860, 862, 864, 866, 868, 870, 872, 874 extend between the first and second printed circuit boards (not shown). Figure 8 A connection post 880 disposed outside the mutual inductance inductor core 102 is also shown. The connection post 880 is used to connect the first and second printed circuit board traces 876, 878 and / or to electrically couple the first and second printed circuit boards (not shown) together. For example, the connection post 880 can be used to couple the power supply and ground circuits of the first and second printed circuit boards (not shown) together. Figure 8 The structure is thus similar to Figure 3A and Figure 3B the structure described Figure 8 Various switching nodes SWN1, SWN1’, SWN2, SWN2’, SWN6, SWN6, GND are also shown and will be discussed with reference to Figure 9 below.

[0087] Figure 9 Shown in an exemplary embodiment corresponding to Figure 8Partial circuit diagram 902 of the electrical configuration of the winding assembly 802. In circuit diagram 902, SWN1, SWN1’, SWN2, SWN2’, SWN6, and SWN6 correspond to the primary winding posts 804, 816, 806, 818, 814, and 826, and the secondary winding posts 852, 864, 854, 866, 862, and 874 are wired in series and grounded at both ends (e.g., the secondary winding posts 852 and 864 are grounded). In this embodiment, circuit diagram 902 implements an adjustment circuit in a multi-phase buck mode with output voltage regulation at Vout. Circuit diagram 902 can be extended to include SWN3 and SWN3’ formed by the primary winding posts 808 and 820 and the secondary winding posts 856 and 868 respectively; SWN4 and SWN4’ formed by the primary winding posts 810 and 822 and the secondary winding posts 858 and 870 respectively; and SWN5 and SWN5’ formed by the primary winding posts 812 and 824 and the secondary winding posts 860 and 872 respectively. In operation, SWN1, SWN1’, SWN2, SWN2’, SWN3, SWN3’, SWN4, SWN4’, SWN5, SWN5’, SWN6, and SWN6’ are switched in a certain pattern to implement a multi-phase buck regulator with output regulation at Vout.

[0088] The exemplary technical effects of the devices described herein include one or more of the following: (a) providing a compact power supply solution using primary and secondary winding posts and connection posts, especially in the vertical direction; (b) placing the switching nodes approximately directly above the primary winding posts to reduce parasitic losses, AC switching losses, and DC losses; (c) configuring the secondary winding posts in a series superposition or series connection, significantly reducing the height of the winding assembly using various mutual inductance inductor cores, thereby increasing the power density of the power module; (d) various configurations of the mutual inductance inductor cores can be used in combination as module elements to scale up or down the power supply solution according to load requirements; and (e) scalability starts from a single-phase regulator with a minimum configuration and can be easily multiplied using the mutual inductance inductor core sub-units described herein to accommodate multiple phases (e.g., up to thirty-two phases or more).

[0089] Although the specific features of various embodiments of the present disclosure may be shown in some of the drawings and not in others, this is merely for convenience. According to the principles of the present disclosure, any feature of any drawing can be cited and / or claimed in combination with any feature of any other drawing.

[0090] This disclosure uses example embodiments that include the best mode and enable one of ordinary skill in the art to practice the embodiments, including making or using any device or system and performing any incorporated method. The patentable scope of this disclosure is defined primarily by the claims and may include other examples that occur to one of ordinary skill in the art. These other examples are intended to fall within the scope of the claims if their structural elements are not different from the literal language of the claims or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

1. A power supply module, characterized in that: Include: a first printed circuit board; a second printed circuit board; a mutual inductor core sandwiched between the first printed circuit board and the second printed circuit board, wherein the mutual inductor core comprises at least one slot to expose the first printed circuit board to the second printed circuit board; as well as At least one conductive pillar extends through the at least one slot to electrically connect the first printed circuit board to the second printed circuit board.

2. The power supply module according to claim 1, characterized in that: The at least one slot comprises a plurality of slots; and The at least one conductive post includes a plurality of pairs of primary and secondary winding posts, each pair of the plurality of pairs of primary and secondary winding posts being disposed in a different one of the plurality of slots.

3. The power supply module according to claim 2, characterized in that: Further comprising a tab extending into one of the plurality of slots, the tab being disposed on one of the plurality of pairs of primary and secondary winding poles and configured to transform a leakage inductance between the pair of the plurality of pairs of primary and secondary winding poles.

4. The power supply module according to claim 2, characterized in that: Further including: A plurality of connection posts are located outside the mutual inductor core and extend between the first printed circuit board and the second printed circuit board; and A plurality of conductive traces are formed on the first printed circuit board and the second printed circuit board, and electrically connect different pairs of the plurality of primary and secondary winding posts together in a winding arrangement through the plurality of connecting posts.

5. The power supply module according to claim 4, characterized in that: The winding arrangement is a tandem winding arrangement.

6. The power supply module according to claim 4, characterized in that: Further included is a toroidal core wrapped around one of the plurality of connecting posts.

7. The power supply module according to claim 1, characterized in that: The mutual inductor core contains: a first side portion; a second side portion; and a central portion sandwiched between the first side portion and the second side portion, The at least one slot includes a plurality of slots formed between the first side portion and the central portion and / or between the second side portion and the central portion.

8. The power supply module according to claim 7, characterized in that: The central portion includes a plurality of crossbars extending toward the first side portion and the second side portion, and the plurality of crossbars define the plurality of slots.

9. The power supply module according to claim 8, characterized in that: The central portion includes at least one tab extending between the plurality of crossbars to one of the plurality of slots.

10. The power supply module according to claim 9, characterized in that: The at least one conductive post includes a primary and secondary winding post, each disposed on a different side of the tab.

11. The power supply module according to claim 8, characterized in that: A first gap is formed between the first side portion and the central portion, a second gap is formed between the second side portion and the central portion, and the first gap and the second gap have a predetermined interval.

12. The power supply module according to claim 11, characterized in that: The first gap and the second gap are filled with a gap spacer.

13. The power supply module according to claim 11, characterized in that: The predetermined spacing varies along a length of the mutual inductor core.

14. The power supply module according to claim 1, characterized in that: The at least one slot comprises a plurality of slots, the at least one conductive column comprises a plurality of primary winding columns, each disposed in one of the plurality of slots and forming a single-turn primary winding for the mutual inductor core; as well as The power supply module further includes a controller configured to perform pulse width modulation phase sequencing of the plurality of primary winding legs based on a configuration of the mutual inductor core.

15. A winding assembly, characterized in that: Include: a first printed circuit board; a second printed circuit board; At least one mutual inductor magnetic core is sandwiched between the first printed circuit board and the second printed circuit board, and each mutual inductor magnetic core comprises: a first side portion; a second side portion; and a central portion sandwiched between the first side portion and the second side portion, the central portion comprising a plurality of cross bars extending toward the first side portion and the second side portion, the plurality of cross bars defining a plurality of slots; as well as A plurality of pairs of conductive posts extend through the plurality of slots to electrically connect the first printed circuit board to the second printed circuit board, each pair of the plurality of pairs of conductive posts forming primary and secondary windings for the at least one mutual inductor core.

16. The winding assembly according to claim 15, characterized in that Further included is a tab extending to one of the plurality of slots, the tab being disposed between one of the plurality of pairs of conductive posts and configured to transform a leakage inductance between one of the primary and secondary windings.

17. The winding assembly according to claim 15, characterized in that Further including: a plurality of connection posts, located outside the at least one mutual inductor core, extending between the first printed circuit board and the second printed circuit board; and A plurality of conductive traces are formed on the first printed circuit board and the second printed circuit board, and electrically connect the primary and secondary windings in a winding arrangement through the plurality of connecting posts.

18. The winding assembly according to claim 17, characterized in that The winding arrangement is a tandem winding arrangement.

19. The winding assembly according to claim 17, characterized in that Further included are a plurality of toroidal cores, each wrapped around one of the plurality of connecting posts.

20. A power supply module, characterized in that: Include: a first printed circuit board; a second printed circuit board; A mutual inductor core is sandwiched between the first printed circuit board and the second printed circuit board, and the mutual inductor core comprises: a first side portion; a second side portion; and a central portion sandwiched between the first side portion and the second side portion, the central portion comprising a plurality of crossbars extending toward the first side portion and the second side portion, the plurality of crossbars defining a plurality of slots; a plurality of pairs of conductive posts extending through the plurality of slots to electrically connect the first printed circuit board to the second printed circuit board, each pair of the plurality of pairs of conductive posts forming a primary and secondary winding for the mutual inductor core; A plurality of connection posts are located outside the mutual inductor core and extend between the first printed circuit board and the second printed circuit board; a plurality of conductive traces formed on the first printed circuit board and the second printed circuit board, electrically connecting the plurality of pairs of conductive posts in a winding arrangement through the plurality of connecting posts; as well as A controller is configured to perform pulse width modulation phase sequencing of the primary winding associated with each of the plurality of pairs of conductive posts.

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