Embedded Magnetic Core Circuit Board for High Inductance
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Solution Overview
Problem
Existing power conversion apparatuses face challenges in achieving high inductance values while minimizing cost due to the need for independent inductors and shield layers, which increase costs and limit the number of winding turns, and the embedded magnetic cores have limited shapes and inductance values.
Innovation Solution
The magnetic core is embedded into the substrate, allowing for flexible winding configurations that can traverse both the surface and inside, enabling multiple turns and various shapes to achieve higher inductance values without the need for shield layers or encapsulation, thus reducing material usage and fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If an independent inductor and shield layer are used, then electromagnetic interference is reduced, but cost increases and device complexity increases
Solution Approach 1:
The patent combines the magnetic core with the substrate to form an integrated structure. The magnetic core is embedded directly into the substrate, eliminating the need for separate inductor components and shield layers. This merging of functions reduces device complexity and cost while maintaining electromagnetic interference protection through the integrated design.
2Ease of manufacture
If the winding travels only through the surface of the inner ring of the magnetic core, then manufacturing is simplified, but the inductance value is small
Solution Approach 1:
The patent extends the winding path from only the surface to both the surface and interior of the magnetic core. The winding travels through the substrate and around the magnetic core in multiple dimensions, increasing the number of effective turns and thus the inductance value, while still maintaining manufacturability through the embedded structure.
3Ease of manufacture
If the embedded magnetic core has a single annular shape, then manufacturing is simplified, but adaptability is limited
Solution Approach 1:
The patent employs magnetic cores with various asymmetric shapes including annular, U-shaped, and E-shaped configurations. These different shapes are embedded in the substrate to provide adaptability for various inductance requirements and application scenarios, while the standardized embedding process maintains ease of manufacture.
4Quantity of substance
If discrete inductors are mounted on substrate, then inductance requirements are met, but substrate area is reduced and power density is improved
Solution Approach 1:
The patent nests the magnetic core within the substrate structure, with the magnetic core embedded into recesses or cavities in the substrate. This nesting approach allows the inductor function to be integrated within the substrate volume rather than occupying additional surface area, thereby maintaining compactness and high power density.
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 allows for customizable inductance values, reduces material and fabrication costs, and enhances the compactness and efficiency of power conversion apparatuses by eliminating the need for independent inductors and shield layers.
Implementation Method 1
a magnetic core 3, where the magnetic core 3 is embedded into the substrate 8... at least one turn of a winding conductor wound around the magnetic core 3 is arranged on the substrate 8
Implementation Method 2
at least one turn of a winding conductor wound around the magnetic core 3 is arranged on the substrate 8, where each turn of the winding conductor includes a first end-surface conductor 41 and a second end-surface conductor 42 that are separately arranged on two ends of the magnetic core 3
Data Source
Figure 1a~1b
Figure 2
Figure 3
AI summary
The present invention is applicable to the field of circuit board technologies, and discloses a circuit board and a power conversion apparatus having the circuit board. The foregoing circuit board includes a substrate and a magnetic core, where the magnetic core is embedded into the substrate, at least one turn of a winding conductor wound around the magnetic core is arranged on the substrate, each turn of the winding conductor includes a first end-surface conductor and a second end-surface conductor that are separately arranged on two ends of the magnetic core, and each turn of the winding conductor further includes a first side-surface conductor that penetrates through the magnetic core from an inner side of the magnetic core and a second side-surface conductor that penetrates through the magnetic core from an outer side of the magnetic core. The power conversion apparatus includes the foregoing circuit board. According to the circuit board and the power conversion apparatus having the circuit board provided by the present invention, the magnetic core is embedded and different manners of winding the magnetic core are used to reduce the usage area of the substrate and flexibly use a wire routing space of a conductive layer of the substrate, which achieves larger inductance, saves materials, and reduces cost for fabricating a power conversion apparatus.