Coupled Inductor Vertical Pillar Stacking Flux Leakage Reduction
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Solution Overview
Problem
Conventional coupled inductors are not suitable for smaller size designs due to volume sacrifices and suffer from flux leakage and slower dynamic speed responses in multiphase Buck/Boost circuits, leading to increased EMI and slower transient responses.
Innovation Solution
A coupled inductor design with two vertically stacked pillars and coils, where the bottom surface of one coil and the top surface of the other are separated by a gap filled with magnetic material, allowing a straight line enclosed by both coils to pass through, enhancing coupling efficiency and reducing size while minimizing EMI.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional lateral pillars design is used, then the inductor can be manufactured, but the volume of magnetic material is sacrificed and size is larger
Solution Approach 1:
The patent transitions from a conventional lateral pillar arrangement to a vertical pillar stacking configuration. This dimensional change allows the magnetic cores to be arranged vertically with coils wound around them, optimizing the use of magnetic material volume while reducing the overall footprint and size of the coupled inductor.
Solution Approach 2:
The patent implements a nested structure where the first coil is wound around the first vertical pillar, the second coil is wound around the second vertical pillar, and both pillars are positioned within the magnetic body. The magnetic material is strategically placed to surround and connect the pillars, creating a compact nested arrangement that maximizes magnetic material utilization while minimizing overall size.
2Object-affected harmful factors
If conventional lateral pillars design is used, then the inductor structure is simple, but flux leakage occurs and EMI increases
Solution Approach 1:
The patent employs an asymmetric vertical stacking configuration where the first and second pillars are positioned at different heights along the vertical axis, with the first pillar having a first height and the second pillar having a second height. This asymmetric arrangement, combined with strategic magnetic material placement, creates optimized magnetic flux paths that reduce leakage and EMI while maintaining structural integrity.
Solution Approach 2:
The patent introduces magnetic material as an intermediary element positioned between and around the vertical pillars. This magnetic material acts as a flux guide and containment structure, directing magnetic flux through intended paths and preventing leakage, thereby reducing EMI without requiring complex shielding structures.
3Speed
If conventional lateral pillars design is used, then the manufacturing process is straightforward, but transient response speed is slower
Solution Approach 1:
The vertical stacking configuration creates shorter magnetic flux path lengths compared to lateral arrangements. This dimensional optimization reduces magnetic reluctance and improves the speed of magnetic flux establishment and collapse, thereby enhancing transient response speed while maintaining manufacturability through standard winding and assembly processes.
Solution Approach 2:
The patent optimizes geometric parameters including the heights of the vertical pillars, the spacing between them, and the distribution of magnetic material. These parameter changes are designed to minimize magnetic path length and maximize coupling efficiency, directly improving transient response characteristics while accommodating conventional manufacturing capabilities.
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 achieves a smaller size and faster dynamic speed response in multiphase Buck/Boost circuits by optimizing magnetic material usage and reducing flux leakage, thereby improving transient response speed and efficiency.
Implementation Method 1
a magnetic material is disposed in the gap and a straight line that is enclosed by each of the first coil and the second coil passes through the two pillars
Implementation Method 2
because the central layer is made of non-magnetic materials, flux leakage can occur from one side of the conventional coupled inductor, which will increase EMI
Data Source
AI summary
A coupled inductor has two pillars that are aligned in a vertical direction, wherein a first coil and a second coil are respectively wound around one of the two pillars, respectively, wherein the bottom surface of winding turns of the first coil and the bottom surface of winding turns of the second coil are separated by a gap, wherein a magnetic material is disposed in the gap and a straight line that is enclosed by each of the first coil and the second coil passes through the two pillars.