Coupled Inductor Assembly With Overlapping Windings for Lower Core Loss
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Solution Overview
Problem
Power converters face challenges in achieving high-power density, high-efficiency, and excellent heat dissipation in space-constrained environments due to increasing load current demands, particularly in high-current, low-voltage applications like server and microprocessor systems.
Innovation Solution
The inductor assembly design features a magnetic core with inverse-coupled windings and optimized pin configurations that reduce current ripple and core loss, allowing for efficient heat dissipation and improved current handling without increasing cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If higher current is used to achieve better processor performance, then power and performance are improved, but heat dissipation becomes more difficult and efficiency deteriorates
Solution Approach 1:
The patent divides the inductor into multiple phases (first phase inductor and second phase inductor) with separate windings and magnetic paths. This segmentation allows each phase to handle a portion of the total current, distributing the heat generation and improving overall heat dissipation efficiency while maintaining high power capability
Solution Approach 2:
The patent utilizes the center leg of the magnetic core as an additional flux path dimension. By routing the third portion and sixth portion of windings around the center leg, it creates a coupled inductor structure that provides an extra magnetic path for flux circulation, reducing core loss and improving efficiency
2Volume of moving object
If smaller size is used to increase power density, then space utilization is improved, but heat conduction becomes more difficult
Solution Approach 1:
The patent combines multiple windings (first, second, third, fourth, fifth, and sixth portions) around a shared magnetic core structure with a common center leg. This merging approach achieves high power density in a compact volume while the coupled magnetic paths facilitate efficient heat conduction through the consolidated structure
3Reliability
If multi-phase power converter is used to reduce output ripple and improve transient performance, then power quality is improved, but device complexity increases
Solution Approach 1:
The patent merges multiple inductor windings into a single coupled inductor assembly with shared magnetic core and integrated pin structure. This consolidation achieves multi-phase power conversion functionality while reducing device complexity compared to using separate inductors for each phase
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 design achieves reduced core loss, enhanced efficiency, and increased current rating by minimizing flux density in the center leg, enabling the use of cost-effective materials and maintaining fast transient response.
Implementation Method 1
The magnetic flux generated by the first and second windings circulates through the outer legs of the magnetic core
Implementation Method 2
The inductor assembly comprises a first winding, a second winding, and a magnetic core
Implementation Method 3
The sixth portion is at least partially over-lapped with the third portion. The third portion and the sixth portion wrap around the center leg
Data Source
AI summary
An inductor assembly comprises a first pin, a second pin, a third pin, a fourth pin, a magnetic core, a first winding and a second winding. The first winding has a first portion extended to form the first pin, a second portion extended to form the fourth pin, and a third portion. The second winding has a fourth portion extended to form the second pin, a fifth portion extended to form the third pin, and a sixth portion at least partially over-lapped with the third portion. The third portion and the sixth portion wrap around a center leg of the magnetic core. The first pin and the second pin are at a first side of the inductor assembly, the third pin and the fourth pin are at a second side of the inductor assembly which opposites the first side.