Concave-Core Voltage Regulator Module for Higher Power Density
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional two-phase coupled buck topologies in voltage regulator modules require two DrMOS devices, leading to increased equivalent dynamic output inductance, larger component size, and reduced power density, failing to meet efficiency and dynamic response requirements.
Innovation Solution
A voltage regulator module with a magnetic core featuring a concave structure that accommodates all passive components on a printed circuit board, reducing module size and enhancing power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional two-phase coupled buck topology with two DrMOS devices is used, then voltage regulation function is achieved, but equivalent dynamic output inductance increases and power density decreases
Solution Approach 1:
The patent merges the inductor and passive components into a single integrated inductor module with a shared magnetic core. The magnetic core serves multiple functions: providing magnetic flux path for inductance, housing passive components (capacitors, resistors) within its structure, and reducing overall component count. This consolidation directly addresses the power density issue by eliminating the need for separate discrete components while maintaining the voltage regulation function.
Solution Approach 2:
The magnetic core is designed as a multi-functional component that simultaneously provides magnetic coupling for the inductor windings and structural housing for passive components. The core's cavities and internal spaces are utilized to accommodate capacitors and other passive elements, making the inductor module serve both electromagnetic function and component mounting function, thereby reducing total module size and increasing power density.
2Reliability
If conventional two-phase coupled buck topology with two DrMOS devices is used, then voltage regulation function is achieved, but equivalent dynamic output inductance increases and response speed decreases
Solution Approach 1:
The integrated inductor module reduces equivalent dynamic output inductance by optimizing the magnetic core structure and winding arrangement. The shared magnetic core provides better magnetic coupling and reduces leakage inductance compared to separate inductors. Additionally, the integrated design reduces parasitic inductance from inter-component connections, resulting in lower overall dynamic output inductance and faster response speed while maintaining voltage regulation capability.
3Device complexity
If passive components are disposed separately on the printed circuit board, then electrical connections are simplified, but module size increases
Solution Approach 1:
The inductor module integrates passive components (capacitors, resistors) within its magnetic core structure, eliminating the need for separate PCB mounting areas. The magnetic core's internal cavities and external surfaces provide mounting locations for passive components, consolidating what would otherwise be separate PCB-mounted components into a single compact module. This significantly reduces overall module size while the integrated structure provides clear electrical connection paths.
Solution Approach 2:
The passive components are nested within the magnetic core structure. The magnetic core acts as a container that houses capacitors and other passive elements in its internal cavities and along its surfaces. This nesting arrangement allows passive components to occupy space that would otherwise be unused, effectively reducing the total volume required for the entire inductor module while maintaining all necessary electrical connections.
Data Source
AI summary
The present disclosure provides a voltage regulator module. The voltage regulator module includes a power element, a passive component, an inductor module and a conductor. The inductor module includes a magnetic core, and the magnetic core includes a concave structure. When the magnetic core is connected and attached to the second surface of a first printed circuit board, the passive component disposed on the second surface of the first printed circuit board is accommodated within the concave structure. The conductor is disposed on the magnetic core and configured to transmit electric power and electric signals. In this way, the size of the voltage regulator module is reduced, and the power density is enhanced.