Embedded Inductor PCB for Single-Reflow Voltage Regulator Modules
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional voltage regulator modules face challenges with increased complexity and cost due to multiple layers and repeated welding processes, which affect production yield and long-term reliability.
Innovation Solution
A PCB component integrating an inductor and circuit paths is embedded in a PCB, allowing for a simplified layer structure and single reflow welding process to connect with power devices and external circuit boards, reducing the number of welding times and enabling flexible manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple layers and repeated welding processes are used in conventional voltage regulator modules, then the structural complexity and reliability are improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The patent merges the inductor, circuit paths, and PCB into a single integrated PCB component with embedded inductor. The inductor winding is embedded within the PCB layers, with electroplated copper layers forming welding positions that connect to power devices. This integration reduces the number of separate components and simplifies the overall module structure while maintaining reliability through single reflow welding process.
Solution Approach 2:
The PCB component serves multiple functions simultaneously: it provides the circuit board structure, embeds the inductor for power regulation, creates welding positions through electroplated copper layers, and establishes electrical connections. This multi-functionality reduces the need for separate components and simplifies the module architecture.
2Reliability
If multiple welding processes are used to connect components, then the connection reliability is improved, but the manufacturing time and production cost increase
Solution Approach 1:
The patent combines multiple welding operations into a single reflow welding process. The electroplated copper layers on the PCB component are designed to be welded simultaneously with power devices in one reflow cycle, eliminating the need for separate welding steps and improving manufacturing efficiency while maintaining connection reliability.
Solution Approach 2:
The electroplated copper layers are prepared in advance during PCB manufacturing, creating pre-formed welding positions that are ready for the final reflow welding process. This preliminary preparation allows all connections to be established in a single welding operation rather than requiring multiple sequential welding steps.
3Manufacturing precision
If multiple welding operations are performed, then the electrical connection quality is improved, but the production cost and manufacturing complexity increase
Solution Approach 1:
The patent integrates the welding positions directly into the PCB structure through electroplated copper layers that are formed during PCB manufacturing. These embedded welding positions are then connected to power devices in a single reflow welding process, simplifying the manufacturing process while ensuring consistent electrical connection quality through controlled copper plating and unified welding.
4Device complexity
If the inductor is integrated into the PCB component, then the device complexity is reduced, but the manufacturing precision requirements increase
Solution Approach 1:
The inductor is integrated into the PCB by embedding the winding within the PCB structure and forming electroplated copper layers that create welding positions. This integration reduces device complexity by eliminating separate inductor components while the precision requirements are managed through controlled electroplating processes that ensure proper electrical connections.
Solution Approach 2:
The electroplated copper layers serve as an intermediary between the embedded inductor winding and the external power devices. This intermediary layer facilitates precise electrical connections without requiring direct exposure of the inductor terminals, allowing for flexible PCB design while maintaining manufacturing precision.
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 approach reduces production costs and improves product quality and reliability by simplifying the manufacturing process and eliminating multiple welding steps, while maintaining performance advantages.
Implementation Method 1
The two output terminals of the inductor winding are integrated with the circuit-board copper in the PCB component through the electroplating process
Data Source
AI summary
A PCB component used in a voltage regulator module and a method for manufacturing the voltage regulator module are disclosed. The PCB component includes a PCB and an inductor. The PCB includes a top surface and a bottom surface. The inductor includes a magnetic core and a winding. The winding runs through the magnetic core, and the winding forms an upper outlet terminal on the upper surface and a lower outlet terminal on the lower surface. The inductor is embedded in the PCB. A plurality of conductive layers are respectively disposed above the upper surface and below the lower surface. The upper outlet terminal and the lower outlet terminal are electrically connected to a power device and an external circuit board. The power device, the PCB component and the external circuit board are stacked vertically in sequence and connected through one reflow welding process to form a voltage regulator module.