Coupled Inductor Structure for Compact Stable Voltage Regulation
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Solution Overview
Problem
Conventional voltage regulators face challenges with large spatial requirements, mechanical instability, high AC losses, and complex control due to small footprint ferrite inductors, which introduce mechanical instability and increased ripple currents, complicating load response.
Innovation Solution
A dual inductor configuration with high coupling and low inductance is used in a trans-inductor voltage regulator (TLVR) topology, featuring a primary and secondary winding embedded in a magnetic material, with a helix structure and dielectric coating for isolation, allowing for smaller dimensions, soft saturation, and stable isolation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If small footprint ferrite inductors are used, then spatial requirements are reduced, but mechanical stability deteriorates
Solution Approach 1:
The patent transitions from vertical stacking (high profile) to horizontal planar integration by embedding inductors in PCB traces. The inductors are formed as planar spiral patterns on the PCB surface, utilizing the PCB's two-dimensional plane rather than vertical space, thereby reducing footprint while maintaining mechanical stability through integration with the rigid PCB substrate.
Solution Approach 2:
The patent combines the inductor structure with the PCB trace system, integrating multiple functions into a unified planar structure. The inductor windings are formed directly on the PCB using conductive traces, eliminating the need for separate discrete inductor components and their associated mechanical stability issues.
2Speed
If more phases are allocated, then response to load changes improves, but spatial requirements increase
Solution Approach 1:
The patent enables multi-phase operation within limited PCB space by using planar spiral inductor patterns that can be densely packed in two dimensions. Multiple phases share the same PCB layer or adjacent layers, utilizing vertical trace routing and ground plane sharing to achieve high phase counts without proportional increases in footprint.
Solution Approach 2:
The PCB trace system serves multiple functions simultaneously: it provides the inductor windings, the current paths, the grounding system, and the interconnection network for multiple phases. This multi-functionality reduces the overall space requirement compared to discrete component implementations where each function requires separate elements.
3Object-generated harmful factors
If low inductance is used, then ripple current is reduced, but AC losses increase
Solution Approach 1:
The patent optimizes the inductor geometry parameters (trace width, trace spacing, spiral dimensions, number of turns) to achieve the desired low inductance value while minimizing AC losses. By carefully controlling the trace cross-section and winding pattern, the design reduces skin effect and proximity effect losses that typically increase with low inductance values.
Solution Approach 2:
The patent uses composite PCB structures with multiple copper layers and optimized ground planes to reduce AC losses. The combination of conductive copper traces, dielectric layers, and ground planes creates a composite structure that minimizes electromagnetic interference and reduces resistive losses at high frequencies.
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 dual inductor configuration enhances mechanical stability, reduces spatial requirements, and improves transient response, minimizing AC losses and the need for large capacitors, enabling efficient voltage regulation with high currents and reduced ripple.
Implementation Method 1
The second winding is magnetically coupled to the first winding and electrically isolated from the first winding. The first and second windings are embedded in the first material of the body. The first material provides a magnetic surrounding of the first winding and of the second winding.
Implementation Method 2
the first winding and the second winding are embedded in the first material of the body. The first material provides a magnetic surrounding of the first winding and of the second winding.
Data Source
AI summary
In an embodiment a coupled inductor includes a body having a first material, a first winding and a second winding magnetically coupled to the first winding and electrically isolated from the first winding, wherein the first winding and the second winding are embedded in the first material of the body, wherein the first material provides a magnetic surrounding of the first winding and the second winding, wherein the first winding has m turns with m>1, and wherein the second winding has n turns with n>1.