Exposed Core Package Design for Power Converter Thermal Management

The patent applies local quality by selectively exposing specific portions of the magnetic core (such as the outer peripheral surface or flux path regions) while encapsulating other portions. This localized exposure strategy provides thermal management benefits at critical heat-generating areas while maintaining mechanical protection where needed, resolving the contradiction between full encapsulation protection and thermal performance.

The patent implements local quality by varying the encapsulant thickness across different regions of the magnetic core. Thinner encapsulant layers are applied in regions where full mechanical protection is less critical or where thermal exposure is desired, while thicker layers are used in regions requiring enhanced protection. This regional variation reduces overall curing time and manufacturing complexity while maintaining adequate mechanical protection.

The patent applies the curvature principle by designing the magnetic core with rounded corners and large radii bends instead of sharp angles and tight bends. This curvature modification reduces flux concentration and eddy current losses in the core while maintaining efficient space utilization. The rounded geometry smooths the flux distribution and eliminates high-stress concentration points, directly addressing the energy loss problem.

The patent applies preliminary action by performing moisture removal and defect prevention measures during the encapsulation process itself rather than requiring separate pre-baking steps. The encapsulation process is designed to accommodate moisture evacuation and prevent void formation inherently, eliminating the need for additional pre-baking equipment and process steps while maintaining high reliability and preventing blistering.