Coupled Inductor Leakage Control via Top Magnetic Element
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Solution Overview
Problem
Existing multiphase coupled inductors face challenges in controlling leakage inductance, which complicates their design and increases their size due to the need for large window widths to accommodate leakage sections, leading to poor volume utilization and complexity in managing magnetic flux.
Innovation Solution
The proposed M-winding coupled inductor design includes a top magnetic element that extends over connecting magnetic elements to provide a path for magnetic flux, allowing for adjustable leakage inductance by varying the thickness of a gap with lower magnetic permeability, thereby reducing the need for large window widths and simplifying the design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If large window widths are used to accommodate leakage sections, then leakage inductance control is improved, but volume utilization deteriorates and device size increases
Solution Approach 1:
The patent introduces a vertical dimension by stacking magnetic cores in multiple layers (first layer, second layer, third layer) connected by connecting portions. This multi-layer configuration allows leakage flux to be controlled through vertical stacking rather than requiring large horizontal window widths, thereby improving volume utilization while maintaining leakage inductance control.
Solution Approach 2:
The inductor is segmented into multiple independent windings (first winding, second winding, third winding, fourth winding) distributed across different layers. Each winding can be independently configured with its own leakage section, allowing precise control of leakage inductance for each phase without requiring large overall window widths.
2Manufacturing precision
If large window widths are used to accommodate leakage sections, then leakage inductance control is improved, but device complexity increases
Solution Approach 1:
The connecting portions serve multiple functions: they electrically connect windings between layers, provide mechanical support, and guide magnetic flux. This multi-functionality reduces the need for separate dedicated leakage sections, simplifying the overall design while maintaining leakage inductance control.
Solution Approach 2:
The patent merges the leakage section function with the connecting portions between layers. The connecting portions simultaneously serve as electrical connectors and as defined paths for leakage flux, eliminating the need for separate large window widths dedicated solely to leakage sections.
3Manufacturing precision
If winding pitch is increased to accommodate leakage sections, then leakage inductance is controlled, but magnetic coupling deteriorates
Solution Approach 1:
By moving leakage flux control to the vertical dimension through multi-layer stacking, the horizontal winding pitch can be minimized. This maintains tight magnetic coupling between adjacent windings in each layer while still providing adequate leakage inductance control through the vertical connecting portions and leakage sections.
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
This design enables more efficient use of the inductor's volume for magnetic coupling, reduces the footprint, and allows for easier adjustment of leakage inductance, leading to improved magnetic coupling, reduced core losses, and increased resistance to saturation.
Implementation Method 1
at least one top magnetic element adjacent to and extending at least partially over at least two of the M connecting magnetic elements to provide a path for magnetic flux between the first and second end magnetic elements
Implementation Method 2
allowing for adjustable leakage inductance by varying the thickness of a gap with lower magnetic permeability
Data Source
AI summary
An M-winding coupled inductor includes a first end magnetic element, a second end magnetic element, M connecting magnetic elements, and M windings. M is an integer greater than one. Each connecting magnetic element is disposed between and connects the first and second end magnetic elements. Each winding is wound at least partially around a respective one of the M connecting magnetic elements. The coupled inductor further includes at least one top magnetic element adjacent to and extending at least partially over at least two of the M connecting magnetic elements to provide a magnetic flux path between the first and second end magnetic elements. The inductor may be included in an M-phase power supply, and the power supply may at least partially power a computer processor.