Low Profile Coupled Inductor Substrate Transient Speed
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Solution Overview
Problem
Existing point-of-load power converters face challenges in achieving high power density and improved transient response due to non-linear inductance with load/current, which affects their performance in portable electronic devices.
Innovation Solution
A low-profile lateral flux inductor structure with inversely coupled windings and a magnetic core design that includes slots to reduce inductance variation with load, utilizing magnetic materials like Permalloy flakes and a multi-layer PCB architecture to enhance power density and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a low-profile lateral flux inductor structure is used to increase power density, then the size and weight of power converters are reduced, but the transient response is limited due to non-linearity of inductance with load/current
Solution Approach 1:
The patent introduces air gaps at specific locations within the magnetic core structure. These localized air gaps create regions of different magnetic permeability, allowing the core to compensate for inductance non-linearity. The air gaps are strategically positioned to control flux distribution and maintain more linear inductance characteristics across varying load conditions, thereby improving transient response while preserving the low-profile design.
Solution Approach 2:
The patent modifies the magnetic core structure by incorporating air gaps, which changes the magnetic circuit parameters. This structural modification alters the inductance characteristics to reduce non-linearity with respect to load current. By changing the physical structure of the core, the patent achieves improved transient response performance without sacrificing the power density benefits of the low-profile design.
2Weight of stationary object
If power converter size is reduced for portable devices, then weight and volume are minimized, but achieving high power density with improved transient response becomes difficult
Solution Approach 1:
The patent embeds the lateral flux inductor structure within a compact multi-layer PCB architecture. The inductor is integrated into the substrate with copper traces forming windings on different layers, allowing three-dimensional utilization of space. This nesting approach enables high power density in a minimal footprint while maintaining the low-profile characteristic essential for portable device weight reduction.
Solution Approach 2:
The patent transitions from traditional planar inductor designs to a three-dimensional multi-layer structure. By utilizing vertical stacking of PCB layers with conductive traces and embedded magnetic materials, the patent achieves higher power density without increasing the planar footprint. This dimensional approach allows more magnetic material and winding turns to be packed into a smaller volume, enhancing power density while keeping weight low.
3Reliability
If inductance non-linearity with load is present, then transient response is limited, but reducing inductance variation with load requires complex magnetic core designs
Solution Approach 1:
The patent divides the magnetic core into multiple segments or regions separated by air gaps. This segmentation allows different portions of the core to operate at different magnetic flux densities, compensating for non-linearity. The divided structure with controlled air gaps creates a more linear overall inductance characteristic across the operating range, improving transient response without requiring overly complex monolithic core designs.
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 significantly increased power density and improved transient response by minimizing inductance non-linearity, allowing for efficient operation across varying loads and reducing the size and weight of power converters, while maintaining high efficiency and reliability.
Implementation Method 1
A low-profile lateral flux inductor structure with inversely coupled windings and a magnetic core design that includes slots to reduce inductance variation with load
Implementation Method 2
slots to reduce inductance variation with load
Implementation Method 3
inversely coupled windings formed by vias in a layer of magnetic material
Implementation Method 4
coupled inductor substrate with transient speed improvement
Data Source
AI summary
A low profile inductor structure suitable for use in a high power density power converter has one or more windings formed by vias through a thin, generally planar body of magnetic material forming the inductor core and conductive cladding on the body of magnetic material or material covering the magnetic material body. Variation of inductance with load current and other operational or environmental parameters is reduced to any desired degree by forming a slot that removes all or a portion of the magnetic material between the locations of the vias.