Embedded Magnetic Core Layout for Compact Power Conversion Modules

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Solution Overview

Problem

Conventional power conversion modules face challenges in optimizing the structure of inductor magnetic cores, leading to inefficient power conversion and increased volume due to uneven loss distribution and low saturation current capabilities, particularly in high-power DC/DC applications.

Innovation Solution

The design incorporates a magnetic component with a magnetic core set and conductor embedded in a main body layer, where the magnetic cores are arranged vertically to reduce parasitic impedance and enhance power density, and the power device is positioned on top for efficient heat dissipation, with optimized pin and capacitor placement to minimize volume and maximize power density.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of stationary object

If a ring-shaped magnetic core is used with sufficient difference between inner diameter and outer diameter, then the magnetic core can be embedded in a multilayer printed circuit board to reduce module size, but the losses in the iron powder magnetic core are unevenly distributed which fails to meet practical requirements

Engineering Contradiction:

Improvemodule sizeVSAvoidloss distribution uniformity

Core Design Contradiction:

Volume of stationary objectVSLoss of energy

Solution Approach 1:

The magnetic core is divided into multiple magnetic core units arranged in an array, where each unit has substantially the same shape and size. This segmentation ensures uniform magnetic flux distribution and equal loss distribution across all units, resolving the uneven loss problem while maintaining compact form factor for PCB embedding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Each magnetic core unit is designed with specific geometric characteristics (substantially the same shape and size) to ensure local uniformity in magnetic properties. The consistent local structure across all units guarantees uniform loss distribution, while the overall array configuration maintains compact volume for integration into multilayer PCBs.

Inventive Principle:

Principle #3Local quality

2Ease of manufacture

If soft-magnetic ferrite is chosen as magnetic core material, then the core can be manufactured with ring shape for PCB embedding, but the saturation magnetization is low resulting in low saturation current

Engineering Contradiction:

Improvecore manufacturingVSAvoidsaturation current

Core Design Contradiction:

Ease of manufactureVSPower

Solution Approach 1:

The patent employs iron powder magnetic core units which combine the advantages of high saturation magnetization (providing high saturation current capability) with manufacturability for PCB embedding. The iron powder material achieves both high power capability and ease of manufacture through its material properties and geometric design.

Inventive Principle:

Principle #40Composite materials

3Temperature

If the top surface of the power device is located at the highest surface to facilitate heat sink installation, then heat dissipation is improved, but the module volume increases

Engineering Contradiction:

Improveheat dissipation efficiencyVSAvoidmodule volume

Core Design Contradiction:

TemperatureVSVolume of stationary object

Solution Approach 1:

The magnetic core units are arranged in a planar array configuration that allows heat sinks to be installed on the top surface of power devices for effective heat dissipation, while the overall module volume is controlled through optimized two-dimensional layout rather than vertical stacking, achieving balance between thermal management and compact size.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 configuration reduces parasitic parameters, enhances power density, and simplifies assembly while effectively dissipating heat, achieving improved efficiency and reduced volume in power conversion modules.

Implementation Method 1

a magnetic component with a magnetic core set and conductor embedded in a main body layer, where the magnetic cores are arranged vertically to reduce parasitic impedance and enhance power density

Methodology Applied

Scientific EffectElectromagnetic Induction: Electromagnetic Induction

Implementation Method 2

the power device is positioned on top for efficient heat dissipation

Methodology Applied

Scientific EffectThermal Conduction: Conduction (thermal)

Implementation Method 3

effectively dissipating heat

Methodology Applied

Scientific EffectConvection: Convection

Data Source

PatentUS20250006415A1Power conversion module and magnetic component thereof

Publication Date: 2025.01.02 DELTA ELECTRONICS INC(CN)

AI summary

The present disclosure provides a power conversion module including a magnetic component and a power device layer. The magnetic component includes a main body layer, a first magnetic core, a second magnetic core and a conductor. The main body layer includes a first surface and a second surface opposite to each other. The first magnetic core is embedded in the main body layer and adjacent to the first surface. The second magnetic core is embedded in the main body layer and adjacent to the second surface. The first magnetic core and the second magnetic core are connected to form plural magnetic columns. The conductor is embedded between the first surface and the second surface. The conductor is partially disposed between the plural magnetic columns. The power device layer is disposed on the first surface. The power device layer includes a power device electrically connected to conductor.