Low-Profile Coupled Winding Structure for Compact High-Current Power Stages
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Solution Overview
Problem
Existing electromagnetic components, particularly those with magnetically coupled windings, are complicated and expensive to manufacture in smaller sizes without compromising performance, especially for high current, high power multi-phase power systems.
Innovation Solution
A low profile surface mount electromagnetic component with a dual-winding arrangement using modular magnetic core pieces and asymmetrical windings, allowing for reduced height and cost-effective manufacturing, while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If conventional electromagnetic components are manufactured in smaller sizes, then component density and space utilization improve, but manufacturing complexity and cost increase significantly
Solution Approach 1:
The magnetic core is divided into multiple modular pieces that can be independently manufactured and then assembled. This segmentation allows each piece to be produced using simpler, more cost-effective processes while maintaining the overall compact design. The modular pieces are joined together to form the complete core structure, enabling small component size without proportionally increasing manufacturing complexity.
Solution Approach 2:
Multiple windings are nested within the modular magnetic core structure, with each winding positioned in specific channels or regions of the core pieces. This nesting arrangement allows for compact integration of multiple functional elements in a small volume, achieving high component density while using standardized manufacturing processes for each nested element.
2Volume of moving object
If conventional electromagnetic components are manufactured in smaller sizes, then component density and space utilization improve, but manufacturing cost increases
Solution Approach 1:
The magnetic core is divided into multiple modular pieces that can be independently manufactured and then assembled. This segmentation allows each piece to be produced using simpler, more cost-effective processes while maintaining the overall compact design. The modular pieces are joined together to form the complete core structure, enabling small component size without proportionally increasing manufacturing complexity.
Solution Approach 2:
The modular magnetic core pieces are designed with universal features that can be used across different component configurations. Standardized channels, mounting features, and connection points allow the same basic modules to serve multiple functions in different applications, reducing tooling costs and enabling economies of scale in manufacturing.
3Reliability
If complex winding arrangements are used to achieve desired magnetic coupling, then electromagnetic performance improves, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The magnetic core is divided into multiple modular pieces that can be independently manufactured and then assembled. This segmentation allows each piece to be produced using simpler, more cost-effective processes while maintaining the overall compact design. The modular pieces are joined together to form the complete core structure, enabling small component size without proportionally increasing manufacturing complexity.
Solution Approach 2:
The modular magnetic core pieces act as intermediaries that facilitate magnetic coupling between windings without requiring complex winding arrangements. The magnetic path provided by the modular core structure enables efficient flux linkage between separately wound coils, achieving desired electromagnetic performance while keeping the winding arrangements relatively simple and manufacturable.
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 enables smaller components with improved manufacturability and reduced complexity, suitable for high current, high power applications, by utilizing simple-shaped windings and magnetic core structures that are easily assembled and scalable.
Implementation Method 1
electrical current flow through the coil(s) or winding(s) in the component generates a magnetic field according to well-known electromagnetic principles that may be harnessed in combination with the magnetic core
Implementation Method 2
one or more dual-winding arrangements, each including a first winding and a second winding magnetically coupled to one another
Data Source
AI summary
A low profile surface mount electromagnetic component for multi-phase electrical power circuitry implemented on a circuit board includes a magnetic core structure and at least one dual-winding arrangement including windings of different thickness but each including an elongated planar main winding section extending linearly across the magnetic core structure. One of the elongated planar main winding sections overlies the other, and a separator element separates the elongated planar main winding sections while the windings remain magnetically coupled to one another.