Composite Power Inductor Layout for Ripple Suppression
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Solution Overview
Problem
Existing switching power source devices require separate inductors for power conversion circuits and output filter circuits, leading to increased component count and physical size, which complicates the suppression of output ripple noises.
Innovation Solution
A composite power inductor is designed with three inductor conductors and a single magnetic body, where the magnetic fluxes generated by currents in the first and second inductor conductors cancel out in the inner leg portion and strengthen in the outer leg portions, while the third inductor conductor forms a low-pass filter, reducing the need for separate components and physical size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate inductors are provided for power conversion circuits and filter circuits, then the desired circuit functions can be realized, but the number of components increases and physical size increases
Solution Approach 1:
The patent combines multiple inductor functions into a single composite power inductor. Specifically, it integrates the power conversion circuit inductor and the output filter circuit inductor into one component, reducing the total number of components while maintaining all necessary circuit functions. The composite inductor includes multiple windings that serve different purposes within the same physical structure.
Solution Approach 2:
The composite power inductor is designed to perform multiple functions simultaneously. It serves as both the power conversion inductor and the output filter inductor, making a single component universal for multiple circuit roles. This multi-functionality is achieved through careful design of the magnetic core and winding arrangements that enable different operational modes within the same device.
2Reliability
If separate inductors are provided for power conversion circuits and filter circuits, then the desired circuit functions can be realized, but the physical size increases
Solution Approach 1:
By merging the power conversion inductor and filter inductor into a single composite component, the patent eliminates the need for separate physical spaces for each inductor. The combined structure occupies less volume than two separate inductors would require, directly reducing the overall physical size of the power source device while maintaining all necessary circuit functions.
3Object-affected harmful factors
If multiple inductors are used for power conversion and filtering, then output ripple noises can be suppressed, but the device complexity increases
Solution Approach 1:
The patent merges the ripple suppression function into the composite power inductor itself. By designing the inductor with multiple windings and appropriate magnetic coupling, the device can suppress output ripple noises internally without requiring separate filter components. This integration simplifies the overall component configuration while maintaining effective ripple suppression.
4Device complexity
If a composite power inductor integrates multiple functions, then the number of components is reduced and physical size is reduced, but magnetic saturation must be suppressed
Solution Approach 1:
The patent applies local quality by creating different magnetic path characteristics in different regions of the composite inductor. The magnetic core is designed with varying properties in different sections to handle the different functional requirements of power conversion and filtering operations. This allows the single component to operate reliably without magnetic saturation by optimizing local magnetic characteristics for each function.
Solution Approach 2:
The patent employs composite magnetic materials or composite structural designs in the magnetic core to achieve both power conversion and filtering functions while preventing magnetic saturation. The composite structure may include different magnetic materials or air gaps strategically placed to manage flux density and prevent saturation under combined operating conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The composite power inductor achieves reduced size, increased efficiency, and improved performance by integrating multiple inductor functions into a single component, suppressing magnetic saturation and output voltage ripples.
Implementation Method 1
a magnetic flux generated by a current flowing through the first inductor conductor and a magnetic flux generated by a current flowing through the second inductor conductor to cancel out each other in an inner leg portion between the first inductor conductor and the second inductor conductor in the magnetic body and to cause the magnetic flux generated by the current flowing through the first inductor conductor and the magnetic flux generated by the current flowing through the second inductor conductor to strengthen each other in outer leg portions
Implementation Method 2
The third inductor conductor forms a low-pass filter for an output current of the power conversion circuits
Data Source
AI summary
A switching power source device equipped with a composite power inductor includes an inductor conductor having a linear shape, an inductor conductor having a linear shape, an inductor conductor, and a single magnetic body configured to form magnetic paths of magnetic fluxes generated by currents flowing through the inductor conductor, the inductor conductor, and the inductor conductor. One end of the inductor conductor is connected to a first input terminal, and another end of the inductor conductor is connected to one end of the inductor conductor. One end of the inductor conductor is connected to a second input terminal, and another end of the inductor conductor is connected to the one end of the inductor conductor. The inductor conductor, the inductor conductor, and the inductor conductor are interposed by or contained in the magnetic body.