Switching power supply system module

Abstract

A switching power supply system module (90) comprises: a plurality of power conversion circuits which each are provided with a switching element and an inductor; an input capacitor; and an output capacitor. The plurality of inductors of the plurality of power conversion circuits form an array inductor (10) which is integrally molded using a plurality of inductor conductors and a magnetic core. A magnetic core (20) has a first magnetic substance part (21) and a second magnetic substance part (22) that are made of differing respective types of magnetic materials. The first magnetic substance part (21) envelops the plurality of inductor conductors so as to be in contact with the plurality of inductor conductors. The second magnetic substance part (22) is integrated with the first magnetic substance part (21) without making contact with the plurality of inductor conductors. The plurality of inductor conductors have: main conductors which are disposed such that a portion of the first magnetic substance part (21) is sandwiched therebetween and which are electrically connected to a common output capacitor; and terminal parts which are connected to ends of the main conductors outside the magnetic core and which are electrically connected to the plurality of switching elements. The switching power supply system module (90) forms a multi-phase converter via the plurality of power conversion circuits, which are provided with the array inductor (10).

Description

Switching Power Supply System Module

[0001] The present invention relates to a switching power supply system module with an array inductor.

[0002] Integrated power supply systems equipped with multiple power conversion circuits have been developed as power supply systems that supply large currents. By incorporating multiple power conversion circuits, the current handled by each power conversion circuit can be reduced, reducing Joule loss. This results in high efficiency and heat dispersion.

[0003] In addition, by operating multiple power conversion circuits in multiphase, the integrated power supply system can be operated at a higher frequency, and the smoothing circuit can be made smaller, thereby achieving a more compact power supply system. Furthermore, in order to accommodate larger currents, it is becoming important to have a scalable power supply system that can flexibly change the number of power conversion circuits to control power according to the magnitude of the output current.

[0004] Each of the plurality of power conversion circuits is configured with an inductor, and the integrated power supply system is configured with a plurality of inductors.

[0005] Examples of configurations using multiple inductors include those described in Patent Documents 1, 2, and 3.

[0006] International Publication No. 2020 / 035968 Japanese Patent Application Publication No. 2021-180199 U.S. Patent Application No. 2013 / 0113596

[0007] However, in conventional configurations such as those shown in Patent Documents 1, 2, and 3, if there is even a small space between the inductor conductor and the magnetic core, the magnetic flux generated by the current flowing through the inductor conductor cannot be utilized to its fullest extent. Furthermore, leakage magnetic flux generates unwanted radiation of electromagnetic noise, causing problems such as malfunction of the power conversion circuit.

[0008] An object of the present invention is to provide a switching power supply system module equipped with an array inductor that can realize a scalable physical structure according to the magnitude of the output current, can make maximum effective use of the magnetic flux generated by the current flowing in the inductor conductor, and can suppress the occurrence of leakage magnetic flux.

[0009] A switching power supply system module according to one embodiment of the present invention includes a plurality of power conversion circuits, each including a switching element and an inductor, an input capacitor, and an output capacitor. The plurality of inductors constituting the plurality of power conversion circuits constitute an array inductor integrally molded using a plurality of inductor conductors and a magnetic core. The magnetic core has a first magnetic portion and a second magnetic portion, each made of a different type of magnetic material. The first magnetic portion is closely attached to and encloses the plurality of inductor conductors. The second magnetic portion is integrated with the first magnetic portion without contacting the plurality of inductor conductors. The plurality of inductor conductors are arranged adjacent to each other with a portion of the first magnetic portion sandwiched therebetween, and include a main conductor electrically connected to a common output capacitor, and a terminal portion connected to an end of the main conductor outside the magnetic core and electrically connected to the plurality of switching elements. The switching power supply system module forms a multi-phase converter using the plurality of power conversion circuits each including an array inductor.

[0010] According to this invention, it is possible to realize a scalable physical structure according to the magnitude of the output current, to make the most effective use of the magnetic flux generated by the current flowing through the inductor conductor, and to suppress the occurrence of leakage magnetic flux.

[0011] FIG. 1 is an equivalent circuit diagram of a switching power supply system module according to a first embodiment of the present invention. FIGS. 2A and 2B are external perspective views of the array inductor according to the first embodiment of the present invention. FIG. 3A is a plan view of the array inductor according to the first embodiment of the present invention, and FIG. 3B is a side view of the array inductor. FIG. 4 is a diagram showing currents flowing through the array inductor according to the first embodiment of the present invention and part of the magnetic flux generated. FIG. 5 is an external perspective view of an array inductor according to a second embodiment of the present invention. FIG. 6A is a plan view of the array inductor according to the second embodiment of the present invention, and FIG. 6B is a side view of the array inductor. FIG. 7 is a diagram showing currents flowing through the array inductor according to the second embodiment of the present invention and part of the magnetic flux generated. FIG. 8 is an external perspective view of an array inductor according to a third embodiment of the present invention. FIG. 9 is an external perspective view of an array inductor according to a fourth embodiment of the present invention. FIG. 10 is an exploded perspective view of a switching power supply system module according to the fourth embodiment of the present invention. FIGS. 11A, 11B, and 11C are external perspective views of array inductors with different numbers of main conductors (inductors).

[0012] First Embodiment A switching power supply system module according to a first embodiment of the present invention will be described with reference to the drawings.

[0013] (Switching power supply system module 90) Fig. 1 is an equivalent circuit diagram of a switching power supply system module according to a first embodiment of the present invention. As shown in Fig. 1, the switching power supply system module 90 includes an input capacitor C91, an MPU 92, a plurality of power semiconductor ICs 931-933 (power semiconductor IC 931, power semiconductor IC 932, and power semiconductor IC 933), an array inductor 10, and an output capacitor C94.

[0014] The power semiconductor IC 931 includes a drive circuit 9310, a switching element Q11, and a switching element Q12. The power semiconductor IC 932 includes a drive circuit 9320, a switching element Q21, and a switching element Q22. The power semiconductor IC 933 includes a drive circuit 9330, a switching element Q31, and a switching element Q32. The switching elements Q11, Q12, Q21, Q22, Q31, and Q32 are power semiconductor elements, such as power MOSFETs.

[0015] The array inductor 10 includes an inductor L31, an inductor L32, and an inductor L33. The inductor L31 includes a terminal PI31 and a terminal PO31. The inductor L32 includes a terminal PI32 and a terminal PO32. The inductor L33 includes a terminal PI33 and a terminal PO33.

[0016] The power semiconductor IC 931 and the inductor L31 form a first power conversion circuit, the power semiconductor IC 932 and the inductor L32 form a second power conversion circuit, and the power semiconductor IC 933 and the inductor L33 form a third power conversion circuit.

[0017] The switching power supply system module 90 includes a pair of input terminals PIH and PIL, and a pair of output terminals POH and POL.

[0018] The positive electrode of a DC power supply is connected to the input terminal PIH. The negative electrode of the DC power supply is connected to the input terminal PIL. The input terminal PIL is connected to a reference potential. In other words, the input terminal PIL is electrically grounded.

[0019] The input capacitor C91 is connected between the input terminals PIH and PIL. The input terminals PIH and PIL are also connected to the MPU 92, so that the MPU 92 receives power from a DC power supply and operates.

[0020] The drain terminal of the switching element Q11 of the power semiconductor IC 931 is connected to the input terminal PIH. The source terminal of the switching element Q11 is connected to the drain terminal of the switching element Q12. The source terminal of the switching element Q12 is connected to the input terminal PIL.

[0021] An input terminal of the drive circuit 9310 is connected to the MPU 92, and an output terminal of the drive circuit 9310 is connected to the gate terminal of the switching element Q11 and the gate terminal of the switching element Q12.

[0022] The drain terminal of the switching element Q21 of the power semiconductor IC 932 is connected to the input terminal PIH. The source terminal of the switching element Q21 is connected to the drain terminal of the switching element Q22. The source terminal of the switching element Q22 is connected to the input terminal PIL.

[0023] An input terminal of the drive circuit 9320 is connected to the MPU 92, and an output terminal of the drive circuit 9320 is connected to the gate terminal of the switching element Q21 and the gate terminal of the switching element Q22.

[0024] The drain terminal of the switching element Q31 of the power semiconductor IC 933 is connected to the input terminal PIH. The source terminal of the switching element Q31 is connected to the drain terminal of the switching element Q32. The source terminal of the switching element Q32 is connected to the input terminal PIL.

[0025] An input terminal of the drive circuit 9330 is connected to the MPU 92, and an output terminal of the drive circuit 9330 is connected to the gate terminal of the switching element Q31 and the gate terminal of the switching element Q32.

[0026] The node between the source terminal of the switching element Q11 and the drain terminal of the switching element Q12 is connected to the terminal PI31 of the inductor L31 of the array inductor 10.

[0027] The node between the source terminal of the switching element Q21 and the drain terminal of the switching element Q22 is connected to the terminal PI32 of the inductor L32 of the array inductor 10.

[0028] The node between the source terminal of the switching element Q31 and the drain terminal of the switching element Q32 is connected to the terminal PI33 of the inductor L33 of the array inductor 10.

[0029] A terminal PO31 of the inductor L31, a terminal PO32 of the inductor L32, and a terminal PO33 of the inductor L33 of the array inductor 10 are connected to each other and to an output terminal POH.

[0030] An output capacitor C94 is connected between the output terminals POH and POL, which is connected to the input terminal PIL.

[0031] A load to which the switching power supply system module 90 supplies power is connected to the output terminals POH and POL.

[0032] In this configuration, the MPU 92 outputs control signals to the multiple power semiconductor ICs 931-933 to control switching with a predetermined phase difference (in this case, a phase difference of 120°). The multiple power semiconductor ICs 931-933 perform switching control based on these control signals. As a result, the switching power supply system module 90 forms a multi-phase converter including a first power conversion circuit configured with the power semiconductor IC 931 and inductor L31, a second power conversion circuit configured with the power semiconductor IC 932 and inductor L32, and a third power conversion circuit configured with the power semiconductor IC 933 and inductor L33.

[0033] In the above explanation, a multi-phase converter having three components (three power conversion circuits) is used as an example, but the number of components is not limited to three, and the switching power supply system module 90 can be configured with any number of components according to the specifications, thereby realizing a scalable physical structure.

[0034] (Array inductor 10) Figures 2(A) and 2(B) are external perspective views of the array inductor according to the first embodiment of the present invention. Figure 2(A) is a diagram clearly illustrating the configuration of the magnetic core, and Figure 2(B) is a diagram clearly illustrating the configuration of the inductor conductor. Figure 3(A) is a plan view of the array inductor according to the first embodiment of the present invention, and Figure 3(B) is a side view of the array inductor. In each diagram illustrating each embodiment of the present invention, the three orthogonal axes are referred to as the X-axis, Y-axis, and Z-axis. However, these are names of axes used to facilitate explanation and do not limit, for example, the direction when the array inductor 10 is in use. The X-axis direction corresponds to the "first direction" in the present invention, and the Z-axis direction corresponds to the "second direction" in the present invention.

[0035] As shown in Figures 2(A), 2(B), 3(A), and 3(B), the array inductor 10 comprises a magnetic core 20, a plurality of main conductors 31-33 (main conductor 31, main conductor 32, main conductor 33), terminal portion 311E, terminal portion 312E, terminal portion 321E, terminal portion 322E, terminal portion 331E, and terminal portion 332E.

[0036] The main conductor 31, the terminal portion 311E, and the terminal portion 312E form a first inductor L31. The main conductor 32, the terminal portion 321E, and the terminal portion 322E form a second inductor L32. The main conductor 33, the terminal portion 331E, and the terminal portion 332E form a third inductor L33.

[0037] (Magnetic core 20) The magnetic core 20 has a substantially rectangular parallelepiped shape with faces parallel to the X-axis direction, the Y-axis direction, and the Z-axis direction (three orthogonal axes). The magnetic core 20 has a first face FD20 and a second face FU20 that are perpendicular to the Z-axis direction. The magnetic core 20 has a third face FE201 and a fourth face FE202 that are perpendicular to the X-axis direction. The magnetic core 20 has a fifth face FS201 and a sixth face FS202 that are perpendicular to the Y-axis direction. The fifth face FS201 corresponds to the "first side face" of the present invention, and the sixth face FS202 corresponds to the "second side face" of the present invention.

[0038] The magnetic core 20 includes a first magnetic part 21 and a second magnetic part 22. The first magnetic part 21 and the second magnetic part 22 are arranged side by side in the Z-axis direction and integrally molded. The first magnetic part 21 is the part on the first surface FD20 side, and the second magnetic part 22 is the part on the second surface FU20 side.

[0039] The first magnetic body part 21 and the second magnetic body part 22 are made of different types of magnetic materials. More specifically, the first magnetic body part 21 and the second magnetic body part 22 are made of a metal alloy magnetic material. The magnetic material that constitutes the metal alloy magnetic material is a metallic magnetic material.

[0040] The first magnetic body 21 and the second magnetic body 22 are formed by powdering a magnetic material, covering the surface with an insulating film, and mixing in a binder. In this case, the first magnetic body 21 and the second magnetic body 22 are made of different components. This allows the first magnetic body 21 and the second magnetic body 22 to have different physical properties and relative permeabilities.

[0041] More specifically, the relative magnetic permeability εr1 of the first magnetic material portion 21 is smaller than the relative magnetic permeability εr2 of the second magnetic material portion 22 (εr1<εr2). Furthermore, the first magnetic material portion 21 has higher adhesion to metal than the second magnetic material portion 22.

[0042] (First Inductor L31) The main conductor 31, the terminal portion 311E, and the terminal portion 312E form a first inductor conductor, and the main conductor 31 is covered with the magnetic core 20 to form the first inductor L31.

[0043] The main conductor 31 is made up of a straight conductor 311, a straight conductor 312, and a straight conductor 313. The straight conductors 311, 312, and 313 are made up of linear conductors or strip conductors having a predetermined width.

[0044] The straight conductors 311 and 312 are arranged parallel to the Y-axis direction and spaced apart in the X-axis direction by a distance (the width d1 of the inner space). One end of each of the straight conductors 311 and 312 in the extending direction is exposed on the fifth surface FS201.

[0045] The straight conductor 313 is arranged parallel to the X-axis direction. The straight conductor 313 connects the other end (the end closer to the sixth surface FS202) of the straight conductor 311 to the other end (the end closer to the sixth surface FS202) of the straight conductor 312. As a result, the main conductor 31 forms a winding conductor that is wound when viewed in the Z-axis direction.

[0046] A terminal portion 311E is connected to one end of the straight conductor 311. The terminal portion 311E is made of a linear conductor or a strip conductor similar to the straight conductor 311. The terminal portion 311E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position substantially flush with the first surface FD20.

[0047] A terminal portion 312E is connected to one end of the straight conductor 312. The terminal portion 312E is made of a linear conductor or a strip conductor similar to the straight conductor 312. The terminal portion 312E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position substantially flush with the first surface FD20.

[0048] The terminal portion 311E corresponds to the first terminal PI31 shown in FIG. 1, and the terminal portion 312E corresponds to the second terminal PO31 shown in FIG.

[0049] (Second Inductor L32) The main conductor 32, the terminal portion 321E, and the terminal portion 322E form a second inductor conductor, and the main conductor 32 is covered with the magnetic core 20 to form the second inductor L32.

[0050] The main conductor 32 is composed of a straight conductor 321, a straight conductor 322, and a straight conductor 323. The straight conductors 321, 322, and 323 are composed of linear conductors or strip conductors having a predetermined width. The main conductor 32 has substantially the same shape as the main conductor 31.

[0051] The straight conductors 321 and 322 are arranged parallel to the Y-axis direction and spaced apart in the X-axis direction by a distance (the width d1 of the inner space). One end of each of the straight conductors 321 and 322 in the extending direction is exposed on the fifth surface FS201.

[0052] The straight conductor 323 is arranged parallel to the X-axis direction. The straight conductor 323 connects the other end (the end closer to the sixth surface FS202) of the straight conductor 321 to the other end (the end closer to the sixth surface FS202) of the straight conductor 322. As a result, the main conductor 32 forms a winding conductor that is wound when viewed in the Z-axis direction.

[0053] A terminal portion 321E is connected to one end of the straight conductor 321. The terminal portion 321E is made of a linear conductor or a strip conductor similar to the straight conductor 321. The terminal portion 321E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position that is substantially flush with the first surface FD20.

[0054] A terminal portion 322E is connected to one end of the straight conductor 322. The terminal portion 322E is made of a linear conductor or a strip conductor similar to the straight conductor 322. The terminal portion 322E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position that is substantially flush with the first surface FD20.

[0055] The terminal portion 321E is the first terminal PI32 shown in Fig. 1, and the terminal portion 322E is the second terminal PO32 shown in Fig. 1. The main conductor 32, the terminal portion 321E, and the terminal portion 322E form a second inductor conductor.

[0056] (Third Inductor L33) The main conductor 33 and the terminal portion 331E and terminal portion 332E form a third inductor conductor, and the main conductor 33 is covered with the magnetic core 20 to form the third inductor L33.

[0057] The main conductor 33 is composed of a straight conductor 331, a straight conductor 332, and a straight conductor 333. The straight conductors 331, 332, and 333 are composed of linear conductors or strip conductors having a predetermined width. The main conductor 33 has substantially the same shape as the main conductors 31 and 32.

[0058] The straight conductors 331 and 332 are arranged parallel to the Y-axis direction and spaced apart in the X-axis direction by a distance d1 (the width of the inner space between the winding conductors). One end of each of the straight conductors 331 and 332 in the extending direction is exposed on the fifth surface FS201.

[0059] The straight conductor 333 is arranged parallel to the X-axis direction. The straight conductor 333 connects the other end (the end closer to the sixth surface FS202) of the straight conductor 331 to the other end (the end closer to the sixth surface FS202) of the straight conductor 332. As a result, the main conductor 33 forms a winding conductor that is wound when viewed in the Z-axis direction.

[0060] A terminal portion 331E is connected to one end of the straight conductor 331. The terminal portion 331E is made of a linear conductor or a strip conductor similar to the straight conductor 331. The terminal portion 331E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position substantially flush with the first surface FD20.

[0061] A terminal portion 332E is connected to one end of the straight conductor 332. The terminal portion 332E is made of a linear conductor or a strip conductor similar to the straight conductor 332. The terminal portion 332E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position that is substantially flush with the first surface FD20.

[0062] The terminal portion 331E corresponds to the first terminal PI33 shown in Fig. 1, and the terminal portion 332E corresponds to the second terminal PO33 shown in Fig. 1. The main conductor 33, the terminal portion 331E, and the terminal portion 332E form a third inductor conductor.

[0063] (Arrangement of Multiple Inductors) The main conductor 31 of the first inductor L31, the main conductor 32 of the second inductor L32, and the main conductor 33 of the third inductor L33 are arranged within the first magnetic part 21 of the magnetic core 20. The positions of the main conductor 31, the main conductor 32, and the main conductor 33 in the Z direction are approximately the same.

[0064] From the fifth surface FS201 toward the sixth surface FS202, the main conductors are arranged in the order of main conductor 31, main conductor 32, and main conductor 33. In this case, in main conductor 31, the straight conductor 311 is arranged closer to the fifth surface FS201 than the straight conductor 312. In main conductor 32, the straight conductor 322 is arranged closer to the fifth surface FS201 than the straight conductor 321. In main conductor 33, the straight conductor 331 is arranged closer to the fifth surface FS201 than the straight conductor 332.

[0065] With this configuration, the straight conductor 312 of the main conductor 31 and the straight conductor 322 of the main conductor 32 are arranged adjacent to each other and parallel to each other at an adjacent distance d2. The straight conductor 321 of the main conductor 32 and the straight conductor 331 of the main conductor 33 are arranged adjacent to each other and parallel to each other at an adjacent distance d2.

[0066] (One Example of a Method for Manufacturing the Array Inductor 10) The array inductor 10 having such a configuration is formed as follows.

[0067] The materials for the first magnetic body part 21 and the second magnetic body part 22 are prepared from the above-mentioned materials.

[0068] The metal (e.g., copper) that will be the material for the first inductor L31, the second inductor L32, and the third inductor L33 is prepared separately from the material for the first magnetic body part 21 and the material for the second magnetic body part 22, and then molded.

[0069] The main conductor 31 , the main conductor 32 , and the main conductor 33 are disposed within the material of the first magnetic part 21 .

[0070] The material of the first magnetic body part 21 and the material of the second magnetic body part 22 are laminated and then heated and molded.

[0071] As a result, the first magnetic material part 21 and the second magnetic material part 22 are molded integrally with the main conductor 31 , the main conductor 32 , and the main conductor 33 enclosed within the first magnetic material part 21 .

[0072] (Example of effect of using the array inductor 10) As described above, the first magnetic material portion 21 has a lower relative permeability than the second magnetic material portion 22, but has a high adhesion to metal. Therefore, the array inductor 10 can prevent gaps from being formed between the first magnetic material portion 21 and the main conductors 31, 32, and 33.

[0073] This increases the adhesion between the main conductor 31, the main conductor 32, and the main conductor 33 and the first magnetic material portion 21. The array inductor 10 can increase the magnetic flux density of the magnetic flux generated in each of the main conductors 31, 32, and 33.

[0074] Furthermore, the second magnetic material portion 22 has a higher relative permeability than the first magnetic material portion 21. As a result, the array inductor 10 can suppress magnetic flux divergence by the second magnetic material portion 22. Therefore, the array inductor 10 can increase the magnetic flux density. Furthermore, although the second magnetic material portion 22 has lower adhesion to metal than the first magnetic material portion 21, this disadvantage does not arise because the second magnetic material portion 22 is not in direct contact with the main conductors 31, 32, and 33. Furthermore, the second magnetic material portion 22 is integrally molded using the same type of material as the first magnetic material portion 21. Therefore, the occurrence of voids at the interface between the second magnetic material portion 22 and the first magnetic material portion 21 is suppressed.

[0075] In this way, the array inductor 10 can achieve a high magnetic flux density and a large inductance despite its small size.

[0076] Furthermore, by enclosing multiple winding conductors (main conductors) within the first magnetic material portion 21 and further providing a second magnetic material portion 22 having a higher relative magnetic permeability than the first magnetic material portion 21 integrally with the first magnetic material portion 21, the array inductor 10 can reduce leakage magnetic flux to the outside and suppress radiation (leakage) of electromagnetic noise into space.

[0077] Furthermore, the first magnetic material part 21 has a lower relative magnetic permeability than the second magnetic material part 22, but is in close contact with the inductor conductor, and can increase the magnetic flux density due to the magnetic flux generated when a current flows through the inductor conductor during power conversion. On the other hand, the second magnetic material part 22 is farther away from the inductor conductor than the first magnetic material part 21, but has a higher relative magnetic permeability than the first magnetic material part 21, and can increase the magnetic flux density due to the magnetic flux generated when a current flows through the inductor conductor during power conversion. In this way, the first magnetic material part 21 and the second magnetic material part 22 can each have a high magnetic flux density, and the distribution of magnetic flux density in the magnetic core can be made uniform, thereby simultaneously achieving a smaller, more efficient, and less noise-inducing integrated power supply system.

[0078] Furthermore, the magnetic structure of the array inductor 10 can be further optimized by adjusting the material of the first magnetic part 21 and the material of the second magnetic part 22. In other words, an optimal array inductor 10 can be configured depending on the specifications of the switching power supply system module 90 in which the array inductor 10 is used.

[0079] The switching power supply system module 90 provides the following advantages.

[0080] The array inductor 10 is small and can produce a large inductance, which improves the efficiency of the switching power supply system module 90. Furthermore, the integrally molded structure makes it possible to uniformly distribute heat in the array inductor 10 and suppress local temperature increases, thereby improving the reliability of the switching power supply system module 90.

[0081] FIG. 4 is a diagram showing a current flowing in the array inductor according to the first embodiment of the present invention and part of the magnetic flux generated.

[0082] 4, adjacent main conductors 31 and 32 have terminals (terminals 312E and 322E) on the output terminal side adjacent to each other in terms of the circuit. Also, adjacent main conductors 32 and 33 have terminals (terminals 321E and 331E) on the input terminal side adjacent to each other in terms of the circuit.

[0083] As a result, the first current flowing through the winding conductor made of main conductor 31 and the second current flowing through the winding conductor made of main conductor 32 flow in opposite directions in plan view. Also, the second current flowing through the winding conductor made of main conductor 32 and the third current flowing through the winding conductor made of main conductor 33 flow in opposite directions in plan view.

[0084] Therefore, the first current flowing through the straight conductor 312 of adjacent main conductors 31 and the second current flowing through the straight conductor 322 of adjacent main conductors 32 flow in the same direction. Also, the second current flowing through the straight conductor 321 of adjacent main conductors 32 and the third current flowing through the straight conductor 331 of adjacent main conductors 33 flow in the same direction.

[0085] 4, the magnetic flux density between the main conductor 31 and the main conductor 32 can be reduced without reducing the magnetic flux density in the inner space of the main conductor 31 or the magnetic flux density in the inner space of the main conductor 32. Similarly, the magnetic flux density between the main conductor 32 and the main conductor 33 can be reduced without reducing the magnetic flux density in the inner space of the main conductor 32 or the magnetic flux density in the inner space of the main conductor 33.

[0086] In this way, by canceling out the magnetic fluxes created by adjacent winding conductors (main conductors), the cross-sectional area of ​​the magnetic core between adjacent winding conductors (main conductors) can be reduced, and the spacing between the winding conductors (main conductors) can be narrowed. Therefore, the array inductor 10 can be made smaller than when multiple inductors are individually constructed and arranged. As a result, the switching power supply system module 90 can also be made smaller.

[0087] Furthermore, by making the switching power supply system module 90 smaller, the heat generation sources (mainly the power semiconductor ICs 931-933) can be concentrated due to the reduced volume, and the cooling structure of the switching power supply system module 90 can be simplified.

[0088] Furthermore, by canceling out magnetic flux between adjacent winding conductors (main conductors) and suppressing magnetic coupling between each winding conductor (main conductor), the switching power supply system module 90 can reduce adverse effects such as reduced power efficiency due to interactions between winding conductors (main conductors).

[0089] Furthermore, in the above-described configuration, the width d1 of the inner space between the winding conductors (main conductors) in the array inductor 10 is made larger than the adjacent distance d2 between adjacent winding conductors (main conductors). By applying such a configuration to the switching power supply system module 90 as described above, the magnetic flux generated in the main conductors 31, 32, and 33 can be increased, and the interaction between the main conductors 31 and 32 and the interaction between the main conductors 32 and 33 can be suppressed, while the array inductor 10 and the switching power supply system module 90 can be made smaller.

[0090] As described above, the switching power supply system module 90 realizes a scalable physical structure according to the magnitude of the output current, while making maximum use of the magnetic flux generated by the current flowing through the inductor conductor, and furthermore, suppressing the occurrence of leakage magnetic flux.

[0091] [Second Embodiment] An array inductor according to a second embodiment of the present invention will be described with reference to the drawings. Fig. 5 is an external perspective view of the array inductor according to the second embodiment of the present invention. Fig. 6(A) is a plan view of the array inductor according to the second embodiment of the present invention, and Fig. 6(B) is a side view of the array inductor.

[0092] As shown in Figures 5, 6(A), and 6(B), the array inductor 10A according to the second embodiment differs from the array inductor 10 according to the first embodiment in that the multiple main conductors 31A, 32A, and 33A are configured in a meandering shape, and in the arrangement of the multiple terminal portions 311E, 312E, 321E, 322E, 331E, and 332E. Other configurations of the array inductor 10A according to the second embodiment are the same as those of the array inductor 10 according to the first embodiment, and a description of similar parts will be omitted. The circuit configuration as a switching power supply system module 90 is the same as that of the first embodiment, and a description thereof will be omitted.

[0093] The array inductor 10A includes a main conductor 31A, a main conductor 32A, and a main conductor 33A. The main conductor 31A, the main conductor 32A, and the main conductor 33A each have a meandering shape.

[0094] The main conductor 31A is composed of a straight conductor 311, a straight conductor 312, a straight conductor 3131, a straight conductor 3132, and a straight conductor 314.

[0095] The linear conductors 311, 312, and 314 are arranged parallel to the Y-axis direction. The linear conductor 314 is arranged between the linear conductors 311 and 312. The linear conductors 311 and 314 are arranged with a distance (width d11 of the inner space) between them in the X-axis direction. The linear conductors 314 and 312 are arranged with a distance (width d12 of the inner space) between them in the X-axis direction.

[0096] One end of the straight conductor 311 in the extension direction is exposed on the fifth surface FS201. One end of the straight conductor 312 in the extension direction is exposed on the sixth surface FS202. The straight conductor 314 is not exposed on the fifth surface FS201 or the sixth surface FS202.

[0097] The straight conductors 3131 and 3132 are arranged parallel to the X-axis direction. The straight conductor 3131 connects the other end of the straight conductor 311 (the end closer to the sixth surface FS202) to one end of the straight conductor 314 (the end closer to the sixth surface FS202). The straight conductor 3132 connects the other end of the straight conductor 314 (the end closer to the fifth surface FS201) to the other end of the straight conductor 312 (the end closer to the fifth surface FS201). As a result, the main conductor 31A forms a meandering conductor when viewed in the Z-axis direction.

[0098] A terminal portion 311E is connected to one end of the straight conductor 311. The terminal portion 311E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position approximately flush with the first surface FD20. A terminal portion 312E is connected to one end of the straight conductor 312. The terminal portion 312E is formed on the sixth surface FS202 of the magnetic core 20 and extends to a position approximately flush with the first surface FD20.

[0099] The terminal portion 311E corresponds to the first terminal PI31 shown in FIG. 1, and the terminal portion 312E corresponds to the second terminal PO31 shown in FIG.

[0100] The main conductor 32A is composed of a straight conductor 321, a straight conductor 322, a straight conductor 3231, a straight conductor 3232, and a straight conductor 324.

[0101] The linear conductors 321, 322, and 324 are arranged parallel to the Y-axis direction. The linear conductor 324 is arranged between the linear conductors 321 and 322. The linear conductors 321 and 324 are arranged with a distance (width d11 of the inner space) between them in the X-axis direction. The linear conductors 324 and 322 are arranged with a distance (width d12 of the inner space) between them in the X-axis direction.

[0102] One end of the straight conductor 321 in the extension direction is exposed on the fifth surface FS201. One end of the straight conductor 322 in the extension direction is exposed on the sixth surface FS202. The straight conductor 324 is not exposed on the fifth surface FS201 or the sixth surface FS202.

[0103] The straight conductors 3231 and 3232 are arranged parallel to the X-axis direction. The straight conductor 3231 connects the other end of the straight conductor 321 (the end closer to the sixth surface FS202) to one end of the straight conductor 324 (the end closer to the sixth surface FS202). The straight conductor 3232 connects the other end of the straight conductor 324 (the end closer to the fifth surface FS201) to the other end of the straight conductor 322 (the end closer to the fifth surface FS201). As a result, the main conductor 32A forms a meander-shaped conductor when viewed in the Z-axis direction.

[0104] A terminal portion 321E is connected to one end of the straight conductor 321. The terminal portion 321E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position approximately flush with the first surface FD20. A terminal portion 322E is connected to one end of the straight conductor 322. The terminal portion 322E is formed on the sixth surface FS202 of the magnetic core 20 and extends to a position approximately flush with the first surface FD20.

[0105] The terminal portion 321E corresponds to the first terminal PI32 shown in FIG. 1, and the terminal portion 322E corresponds to the second terminal PO32 shown in FIG.

[0106] The main conductor 33A is composed of a straight conductor 331, a straight conductor 332, a straight conductor 3331, a straight conductor 3332, and a straight conductor 334.

[0107] The linear conductors 331, 332, and 334 are arranged parallel to the Y-axis direction. The linear conductor 334 is arranged between the linear conductors 331 and 332. The linear conductors 331 and 334 are arranged with a distance (width d11 of the inner space) in the X-axis direction. The linear conductors 334 and 332 are arranged with a distance (width d12 of the inner space) in the X-axis direction.

[0108] One end of the straight conductor 331 in the extension direction is exposed on the fifth surface FS201. One end of the straight conductor 332 in the extension direction is exposed on the sixth surface FS202. The straight conductor 334 is not exposed on the fifth surface FS201 or the sixth surface FS202.

[0109] The straight conductors 3331 and 3332 are arranged parallel to the X-axis direction. The straight conductor 3331 connects the other end of the straight conductor 331 (the end closer to the sixth surface FS202) to one end of the straight conductor 334 (the end closer to the sixth surface FS202). The straight conductor 3332 connects the other end of the straight conductor 334 (the end closer to the fifth surface FS201) to the other end of the straight conductor 332 (the end closer to the fifth surface FS201). This makes the main conductor 33A a meandering conductor when viewed in the Z-axis direction.

[0110] A terminal portion 331E is connected to one end of the straight conductor 331. The terminal portion 331E is formed on the fifth surface FS201 of the magnetic core 20 and extends to a position approximately flush with the first surface FD20. A terminal portion 332E is connected to one end of the straight conductor 332. The terminal portion 332E is formed on the sixth surface FS202 of the magnetic core 20 and extends to a position approximately flush with the first surface FD20.

[0111] The terminal portion 331E corresponds to the first terminal PI33 shown in FIG. 1, and the terminal portion 332E corresponds to the second terminal PO33 shown in FIG.

[0112] The main conductor 31A, the main conductor 32A, and the main conductor 33A are disposed within the first magnetic material portion 21 of the magnetic material core 20. The positions of the main conductor 31A, the main conductor 32A, and the main conductor 33A in the Z direction are approximately the same.

[0113] The main conductors are arranged in the order of main conductor 31A, main conductor 32A, and main conductor 33A from fifth surface FS201 to sixth surface FS202. In this case, in main conductor 31A, straight conductor 311 is arranged closer to the fifth surface FS201 than straight conductor 312. In main conductor 32A, straight conductor 321 is arranged closer to the fifth surface FS201 than straight conductor 322. In main conductor 33A, straight conductor 331 is arranged closer to the fifth surface FS201 than straight conductor 332.

[0114] With this configuration, the straight conductor 312 of the main conductor 31A and the straight conductor 321 of the main conductor 32A are arranged adjacent to each other and parallel to each other at an adjacent distance d2. The straight conductor 322 of the main conductor 32A and the straight conductor 331 of the main conductor 33 are arranged adjacent to each other and parallel to each other at an adjacent distance d2.

[0115] With this configuration, the array inductor 10A can achieve the same effects as the array inductor 10.

[0116] For example, FIG. 7 is a diagram showing a current flowing through an array inductor according to a second embodiment of the present invention and part of the magnetic flux generated.

[0117] 7 , in adjacent main conductors 31A and 32A, the first current (switching current) flowing in the straight conductor 312 of the adjacent main conductor 31A and the second current (switching current) flowing in the straight conductor 321 of the adjacent main conductor 32A flow in the same direction. In adjacent main conductors 32A and 33A, the second current (switching current) flowing in the straight conductor 322 of the adjacent main conductor 32A and the third current (switching current) flowing in the straight conductor 331 of the main conductor 33A flow in the same direction.

[0118] This allows the magnetic flux density between main conductor 31A and main conductor 32A to be reduced without reducing the magnetic flux density in the inner space of main conductor 31A or 32A, as shown in Figure 7. Similarly, the magnetic flux density between main conductor 32A and main conductor 33A can be reduced without reducing the magnetic flux density in the inner space of main conductor 32A or 33A.

[0119] Furthermore, in this configuration, the input terminal and output terminal of each of the main conductors 31A, 32A, and 33A can be arranged on the opposite side of the magnetic core 20.

[0120] [Third Embodiment] An array inductor according to a third embodiment of the present invention will be described with reference to the drawings. Fig. 8 is a perspective view showing the appearance of the array inductor according to the third embodiment of the present invention.

[0121] 8, the array inductor 10B according to the third embodiment differs from the array inductor 10 according to the first embodiment in the configuration of the magnetic core 20B. Other configurations of the array inductor 10B according to the third embodiment are similar to those of the array inductor 10 according to the first embodiment, and a description of similar parts will be omitted. The circuit configuration as a switching power supply system module 90 is similar to that of the first embodiment, and a description thereof will be omitted.

[0122] The magnetic core 20B includes a first magnetic material portion 21, a second magnetic material portion 22, and a second magnetic material portion 23. The second magnetic material portion 22 and the second magnetic material portion 23 in this embodiment correspond to the "third magnetic material portion" and the "fourth magnetic material portion" in the claims.

[0123] The second magnetic material portion 22 and the second magnetic material portion 23 are made of the same composition.

[0124] The second magnetic material portion 22 and the second magnetic material portion 23 are arranged to sandwich the first magnetic material portion 21 in the Z-axis direction.

[0125] The multiple main conductors 31 , 32 , 33 are contained within the first magnetic material portion 21 .

[0126] With this configuration, the array inductor 10B can achieve the same effects as the array inductor 10 according to the first embodiment.

[0127] Furthermore, the array inductor 10B can be further miniaturized, and leakage of magnetic flux to the outside can be further suppressed.

[0128] [Fourth Embodiment] An array inductor according to a fourth embodiment of the present invention will be described with reference to the drawings. Fig. 9 is an external perspective view of the array inductor according to the fourth embodiment of the present invention. Fig. 10 is an exploded perspective view of the switching power supply system module according to the fourth embodiment of the present invention.

[0129] 9, the array inductor 10C according to the fourth embodiment differs from the array inductor 10 according to the first embodiment in the configuration of the magnetic core 20C, the number of inductors, and the configuration of the terminal portion. Other configurations of the array inductor 10C according to the fourth embodiment are the same as those of the array inductor 10 according to the first embodiment, and a description of similar parts will be omitted.

[0130] 10 , the switching power supply system module 90C according to the fourth embodiment differs from the switching power supply system module 90 according to the first embodiment in the number of power conversion circuits. Other configurations of the switching power supply system module 90C according to the fourth embodiment are similar to those of the switching power supply system module 90 according to the first embodiment, and detailed description thereof will be omitted.

[0131] As shown in FIG. 9, the array inductor 10C includes a magnetic core 20C, a plurality of main conductors 31 and 32, and a plurality of terminal portions 311E, 312E, 321E, and 322E.

[0132] The magnetic core 20C includes a first magnetic material portion 21 and a plurality of second magnetic material portions 22, 23. The first magnetic material portion 21 and the plurality of second magnetic material portions 22, 23 are integrally formed. The second magnetic material portion 22 and the second magnetic material portion 23 sandwich the first magnetic material portion 21 in the Z-axis direction. The second magnetic material portion 22 forms a second surface FU20 of the magnetic core 20C, and the second magnetic material portion 23 forms a first surface FD20 of the magnetic core 20C.

[0133] The main conductor 31 and the main conductor 32 are formed of winding conductors as described above. The main conductor 31 and the main conductor 32 are contained within the first magnetic material portion 21. The main conductor 31 and the main conductor 32 are arranged side by side in the X-axis direction.

[0134] Terminal portion 311E and terminal portion 312E are formed on fifth surface FS201 and connected to main conductor 31. Terminal portion 311E has a shape that extends to first surface FD20. Terminal portion 312E has a shape that extends to second surface FU20.

[0135] Terminal portion 321E and terminal portion 322E are formed on fifth face FS201 and connected to main conductor 32. Terminal portion 321E has a shape that extends to first face FD20. Terminal portion 322E has a shape that extends to second face FU20.

[0136] In this way, the terminal portions connected to both ends of the main conductor may extend in different directions.

[0137] As shown in FIG. 10 , the switching power supply system module 90C includes an array inductor 10C, a circuit board 991, a circuit board 992, a power semiconductor IC 931, a power semiconductor IC 932, a plurality of capacitors 910, a plurality of capacitors 940, and a plurality of connecting conductors 998.

[0138] The circuit board 991 is plate-shaped and has a front surface 9911 and a back surface 9912. The circuit board 991 is mainly made of an insulating material and has conductor patterns formed thereon to implement the switching power supply system module 90C. The back surface 9912 of the circuit board 991 has conductor patterns formed thereon that constitute the input terminals PIH, PIL, output terminals POH, and output terminals POL.

[0139] The circuit board 992 is plate-shaped and has a front surface 9921 and a back surface 9922. The circuit board 992 is mainly made of an insulating material, and has a conductor pattern formed thereon to realize the switching power supply system module 90C.

[0140] The circuit board 991 and the circuit board 992 are arranged at a distance from each other so that a surface 9911 of the circuit board 991 faces a back surface 9922 of the circuit board 992 .

[0141] The plurality of capacitors 910 constitute the input capacitor C91 in Figure 1. The plurality of capacitors 940 constitute the output capacitor C94 in Figure 1.

[0142] The plurality of connection conductors 998 are formed of a metal plate or an insulating substrate on which a conductor is formed.

[0143] The array inductor 10C and the plurality of capacitors 940 are mounted on a surface 9911 of the circuit board 991. At this time, the array inductor 10C is arranged so as to cover at least a part of the mounting area of ​​the plurality of capacitors 940.

[0144] The array inductor 10C is mounted on the surface 9911 of the circuit board 991 by joining the terminal portions 311E and 321E to the conductor patterns on the surface 9911 of the circuit board 991 .

[0145] The power semiconductor IC 931, the power semiconductor IC 932, and the plurality of capacitors 910 are mounted on a circuit board 992. The power semiconductor IC 931 and some of the plurality of capacitors 910 are mounted on a front surface 9921 of the circuit board 992. The power semiconductor IC 932 and other parts of the plurality of capacitors 910 are mounted on a back surface 9922 of the circuit board 992.

[0146] Furthermore, the terminal portion 312E and the terminal portion 322E of the array inductor 10C are connected to the rear surface 9922 of the circuit board 992.

[0147] A plurality of connection conductors 998 are connected to a front surface 9911 of the circuit board 991 and a rear surface 9922 of the circuit board 992 .

[0148] With this configuration, the switching power supply system module 90C physically configures a circuit that is configured with two power conversion circuits in the switching power supply system module 90 shown in FIG.

[0149] In this case, the power semiconductor IC 931, the power semiconductor IC 932, and the array inductor 10C overlap when viewed in the Z-axis direction (in plan view). This allows the switching power supply system module 90C to be made compact in plan view. And because the array inductor 10C is configured to be compact as described above, the switching power supply system module 90C can also be configured to be even more compact.

[0150] In addition, in this configuration, the array inductor 10C also functions as a connecting conductor between the circuit board 991 and the circuit board 992. Therefore, the transmission path of the current passing through the array inductor 10C can be shortened, and loss can be suppressed.

[0151] This structure also reduces the volume of the switching power supply system module 90C, allowing the heat source to be concentrated within the volume of the switching power supply system module 90C. This allows the switching power supply system module 90C to be effectively cooled, for example, by installing a heat sink or the like on the top surface of the power semiconductor IC 931. This configuration also simplifies the cooling structure of the switching power supply system module 90C.

[0152] 11(A), 11(B), and 11(C) are external perspective views of array inductors with different numbers of main conductors (inductors). Fig. 11(A) has three main conductors, Fig. 11(B) has two main conductors, and Fig. 11(C) has four main conductors.

[0153] As shown in FIG. 11A, the array inductor 10X1 includes a magnetic core 20 consisting of a first magnetic part 21 and a second magnetic part 22, a plurality of main conductors 31, 32, and 33, and a plurality of terminal parts 311E, 312E, 321E, 322E, 331E, and 332E.

[0154] As shown in FIG. 11B, the array inductor 10X2 includes a magnetic core 20 composed of a first magnetic part 21 and a second magnetic part 22, a plurality of main conductors 31, 32, and a plurality of terminal parts 311E, 312E, 321E, 322E.

[0155] As shown in Figure 11 (C), the array inductor 10X3 includes a magnetic core 20 consisting of a first magnetic part 21 and a second magnetic part 22, multiple main conductors 31, 32, 33, and 34, and multiple terminal parts 311E, 312E, 321E, 322E, 331E, 332E, 341E, and 342E.

[0156] 11(A), 11(B), and 11(C), the array inductors 10X1, 10X2, and 10X3 differ only in the number of main conductors and terminal portions, and the shapes of the main conductors and terminal portions are substantially the same. Furthermore, although the dimensions of the magnetic core 20 vary depending on the number of main conductors contained therein, the basic shape is the same.

[0157] In this way, by using the array inductor structure according to the embodiment of the present invention, it is possible to configure a scalable array inductor by adjusting the number of components as needed. Because the basic structures of the main conductor, terminal portion, and magnetic core are the same, it is possible to shorten the design period for the array inductor and reduce manufacturing costs.

[0158] In the array inductors shown in the above-described embodiments, the main conductor is a wound conductor or a meandering conductor when viewed from above (when viewed in a direction perpendicular to the first surface FD20 and the second surface FU20). However, the main conductor may also be a wound conductor or a meandering conductor when viewed from the side (when viewed in a direction parallel to the first surface FD20 and the second surface FU20). In this case, the main conductor only needs to be enclosed within the first magnetic material portion 21 and positioned so as not to come into contact with the second magnetic material portion 22 or the second magnetic material portion 23.

[0159] Furthermore, the configurations of the above-described embodiments can be combined as appropriate, and effects can be achieved according to the combination.

[0160] <1> A switching power supply system module including a plurality of power conversion circuits, each including a switching element and an inductor, an input capacitor, and an output capacitor, wherein the plurality of inductors configuring the plurality of power conversion circuits configure an array inductor integrally formed using a plurality of inductor conductors and a magnetic core, the magnetic core having a first magnetic part and a second magnetic part made of different types of magnetic material, the first magnetic part closely contacting and enclosing the plurality of inductor conductors, the second magnetic part being integrated with the first magnetic part without contacting the plurality of inductor conductors, the plurality of inductor conductors being arranged adjacent to each other with a part of the first magnetic part sandwiched between them, and having a main conductor electrically connected to the common output capacitor, and a terminal part connected to an end of the main conductor outside the magnetic core and electrically connected to the plurality of switching elements, and wherein the switching power supply system module configures a multi-phase converter using the plurality of power conversion circuits including the array inductor.

[0161] <2> The switching power supply system module according to <1>, wherein main conductors of the plurality of inductor conductors are winding conductors, and the multi-phase converter causes currents to flow in opposite directions in adjacent winding conductors and currents to flow in the same direction in adjacent parallel running portions of the winding conductors, and the magnetic core causes generated magnetic fluxes to cancel each other out in a space where the plurality of winding conductors are adjacent, and generates magnetic fluxes to reinforce each other in an inner space surrounded by the winding conductors, due to the currents flowing in the plurality of winding conductors.

[0162] <3> The switching power supply system module according to <1> or <2>, wherein the first magnetic body portion and the second magnetic body portion each have a structure in which a surface of a powder magnetic material is covered with an insulating film, a binder is used, and the different constituent compositions are integrally molded using hot molding.

[0163] <4> The switching power supply system module according to any one of <1> to <3>, wherein the second magnetic material portion includes a third magnetic material portion and a fourth magnetic material portion, wherein main conductors of the plurality of inductor conductors are arranged side by side in a first direction while being enclosed within the first magnetic material portion, and wherein the third magnetic material portion and the fourth magnetic material portion sandwich the first magnetic material portion from both sides in a second direction perpendicular to the first direction.

[0164] <5> The switching power supply system module according to any one of <1> to <4>, wherein the relative magnetic permeability of the first magnetic material portion is smaller than the relative magnetic permeability of the second magnetic material portion.

[0165] <6> The switching power supply system module according to <3>, wherein the first magnetic body portion and the second magnetic body portion are made of a metal alloy magnetic material.

[0166] <7> The switching power supply system module according to <3>, wherein the magnetic material is made of a metallic magnetic material.

[0167] <8> The switching power supply system module according to <2>, wherein the distance between adjacent winding conductors is equal to or less than the width of an inner space surrounded by the winding conductors.

[0168] <9> The switching power supply system module according to any one of <1> to <8>, wherein the inductor conductor is a linear conductor or a strip conductor that is formed in advance separately from the magnetic core.

[0169] <10> The switching power supply system module according to any one of <1> to <9>, wherein the plurality of inductor conductors comprise: a meandering main conductor; and the terminal portions are a first terminal portion connected to one end of the main conductor and a second terminal portion connected to the other end of the main conductor; the magnetic core has first and second side surfaces parallel to a direction in which the plurality of inductor conductors are arranged; the plurality of first terminal portions are arranged on the first side surface; and the plurality of second terminal portions are arranged on the second side surface; and the multi-phase converter causes switching currents flowing through the plurality of inductor conductors to flow in the same direction.

[0170] 10, 10A, 10B, 10C, 10X1, 10X2, 10X3: array inductor 20, 20B, 20C: magnetic core 21: first magnetic part 22, 23: second magnetic part L31, L32, L33: inductor 31, 31A, 32, 32A, 33, 33A: main conductor 90, 90C: switching power supply system module 92: MPU 311, 312, 313, 314, 321, 322, 323, 324, 331, 332, 333, 334, 3131, 3132, 3231, 3232, 3331, 3332: straight conductor 311E, 312E, 321E, 322E, 331E, 332E: terminal part 910, 940: Capacitors 931, 932, 933: Power semiconductor ICs 991, 992: Circuit boards 9310, 9320, 9330: Drive circuits L31, L32, L33: Inductors PI31, PI32, PI33: First terminals PIH, PIL: Input terminals PO31, PO32, PO33: Second terminals POH, POL: Output terminals Q11, Q12, Q21, Q22, Q31, Q32: Switching elements C91: Input capacitor C94: Output capacitor d1, d11, d12: Width d2: Adjacent distance FD20: First surface FU20: Second surface FE201: Third surface FE202: Fourth surface FS201: Fifth surface FS202: Sixth surface

Claims

1. A switching power supply system module comprising a plurality of power conversion circuits, each equipped with a switching element and an inductor, an input capacitor, and an output capacitor, The multiple inductors constituting the multiple power conversion circuits constitute an array inductor integrally molded using multiple inductor conductors and a magnetic core. The magnetic core has a first magnetic part and a second magnetic part, each made of a different type of magnetic material. The first magnetic material portion is in close contact with and encloses the plurality of inductor conductors, The second magnetic material portion is integrated with the first magnetic material portion without contacting the plurality of inductor conductors. The plurality of inductor conductors are, A main body is arranged adjacent to each other with a portion of the first magnetic material in between, and is electrically connected to the common output capacitor, A terminal portion is connected to the end of the main body outside the magnetic core and electrically connected to a plurality of switching elements, It has, A multiphase converter is configured by the multiple power conversion circuits, each of which is equipped with the aforementioned array inductor. Switching power supply system module.

2. The leading members of the aforementioned plurality of inductor conductors are wound conductors, The aforementioned multiphase converter is The current flowing through the adjacent winding conductor is in the opposite direction. The current flowing in adjacent parallel sections of the winding conductor is in the same direction. The aforementioned magnetic core is As current flows through the aforementioned multiple winding conductors, the generated magnetic flux cancels out in the space where the multiple winding conductors are adjacent to each other. In the inner space surrounded by the aforementioned winding conductor, the generated magnetic flux reinforces each other. A switching power supply system module according to claim 1.

3. The first magnetic material portion and the second magnetic material portion are Each structure is formed by covering the surface of a powdered magnetic material with an insulating film, using a binder, and integrally molding it using heat molding with different component compositions. A switching power supply system module according to claim 1 or claim 2.

4. The second magnetic material portion comprises a third magnetic material portion and a fourth magnetic material portion. The leading bodies of the plurality of inductor conductors are arranged in a first direction while being enclosed within the first magnetic material portion. The third magnetic material portion and the fourth magnetic material portion sandwich the first magnetic material portion from both sides in a second direction perpendicular to the first direction. A switching power supply system module according to claim 1 or claim 2.

5. The relative permeability of the first magnetic material is smaller than the relative permeability of the second magnetic material. A switching power supply system module according to claim 1 or claim 2.

6. The first magnetic material portion and the second magnetic material portion are made of a metal alloy magnetic material. A switching power supply system module according to claim 3.

7. The magnetic material is made of a metallic magnetic material. A switching power supply system module according to claim 3.

8. The distance between adjacent winding conductors is less than or equal to the width of the inner space enclosed by the winding conductors. The switching power supply system module according to claim 2.

9. The inductor conductor is a linear or strip-shaped conductor that is formed separately from the magnetic core. A switching power supply system module according to claim 1 or claim 2.

10. The plurality of inductor conductors are, A meander-shaped principal body, The terminal portion includes a first terminal portion connected to one end of the main body and a second terminal portion connected to the other end of the main body. Equipped with, The magnetic core has a first side surface and a second side surface parallel to the direction in which the plurality of inductor conductors are aligned, The plurality of first terminal portions are arranged on the first side surface, The plurality of second terminal portions are arranged on the second side surface, The aforementioned multiphase converter is The switching currents flowing through the aforementioned plurality of inductor conductors are directed in the same direction. A switching power supply system module according to claim 1 or claim 2.