Composite Magnetic Material for Coreless Integrated Power Inductors
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Solution Overview
Problem
The challenge of integrating power converters or power regulators with higher power handling capability yet smaller size is hindered by the large physical volume of conventional discrete inductive components, limiting the integration and power density of power management devices.
Innovation Solution
Integration of a power switching unit and inductive energy storage device within a packaged module encapsulated by a magnetic molding compound, eliminating the need for a magnetic core and conventional molding compound, thereby reducing size and enhancing thermal conductivity and power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional discrete inductive components are used, then the inductor can provide necessary energy storage, but the physical volume becomes large, limiting integration density and power handling capability
Solution Approach 1:
The patent combines the inductor and power switching unit into a single integrated packaged module. The inductor is directly mounted on the substrate within the same package as the power switching unit, eliminating the need for separate discrete components. This merging of components achieves higher power handling capability while reducing overall physical volume and improving integration density.
2Temperature
If conventional molding compound is used to encapsulate the module, then the components are protected, but the thermal conductivity is insufficient, limiting heat dissipation efficiency
Solution Approach 1:
The patent uses a magnetic molding compound with enhanced thermal conductivity properties to encapsulate the integrated module. This composite material provides both mechanical protection for the components and superior thermal dissipation pathways. The magnetic molding compound contains magnetic particles that improve thermal conduction while maintaining the protective encapsulation function, thus resolving the contradiction between component protection and thermal management.
3Power
If a magnetic core is used in the inductor, then the inductance value can be achieved, but the overall size of the inductive component increases
Solution Approach 1:
The patent achieves the required inductance value by optimizing the winding configuration and turns of the inductor rather than relying on a large magnetic core. The inductor is designed with multiple turns of conductive material in a compact arrangement that provides sufficient inductance without requiring a bulky core structure. This parameter optimization allows achieving the necessary inductance while maintaining a compact form factor that fits within the integrated packaged module.
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 solution achieves a smaller form factor and improved power density with enhanced thermal dissipation and efficiency, overcoming the limitations of conventional discrete inductor-based designs.
Implementation Method 1
enhancing thermal conductivity and power density
Implementation Method 2
Composite magnetic material providing high magnetic permeability
Data Source
AI summary
A composite magnetic material including a composite non-magnetic material (MA) and a magnetic filler (MB). The magnetic filler (MB) includes coated magnetic particles dispersed in the composite non-magnetic material (MA). The coated magnetic particles (MB) include magnetic metal particles (MB1) that are surface coated with an insulation coating layer (MB2). The composite magnetic material provides a high relative magnetic permeability no lower than 13 at a frequency of no greater than 200 MHz.