Flat-Wound Magnetic Element for Even Current Distribution
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Solution Overview
Problem
The existing magnetic elements in data processing systems, particularly in data centers, face challenges with uneven current distribution due to the vertical-winding structure of metal windings, leading to increased power consumption and reduced efficiency.
Innovation Solution
A magnetic element with a multi-turn metal winding structure is created by mechanically dividing the metal wiring layer into vertical and horizontal portions, ensuring even current distribution through a manufacturing process that includes forming an insulation layer and metallizing the magnetic core, followed by a mechanically dividing process to achieve a flat wound structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a vertical-winding structure is used for metal windings on PCB wiring layers, then the winding can be formed in the wiring layer with the magnetic column perpendicular to the PCB, but the current distribution becomes uneven and power consumption increases
Solution Approach 1:
The patent segments the single vertical winding into multiple parallel windings (at least two windings). Each winding carries a portion of the total current, distributing the current more evenly across the winding structure. This segmentation reduces the harmful concentration of current in the outer parts of a single vertical winding, thereby reducing power consumption and energy loss.
Solution Approach 2:
The patent introduces horizontal portions in the windings that are positioned at different distances from the magnetic column. The horizontal portions have different impedances (inner horizontal portion has higher impedance, outer horizontal portion has lower impedance), creating local quality variations that balance the current distribution throughout the winding structure, reducing hotspots and energy loss.
2Ease of operation
If a vertical-winding structure with vias connecting parallel wiring layers is used, then the wiring layers can be connected through vias, but the via length increases and via loss becomes significant
Solution Approach 1:
The patent transitions from a purely vertical via connection approach to a hybrid structure combining vertical and horizontal portions. The horizontal portions extend the current path in the horizontal dimension, providing alternative current pathways that reduce reliance on long vertical vias. This dimensional change shortens the effective via length and reduces via loss by distributing the current path across multiple dimensions.
3Ease of manufacture
If the metal winding is formed as a ring in horizontal direction with vertical winding structure, then the winding can be completed, but the impedance varies between outer and inner parts resulting in uneven current distribution
Solution Approach 1:
The patent deliberately introduces asymmetry in the winding structure by having horizontal portions at different distances from the magnetic column. The inner horizontal portion and outer horizontal portion have different lengths and impedances, creating an asymmetric structure that compensates for the natural impedance gradient in vertical windings. This controlled asymmetry balances the overall current distribution, ensuring more uniform current flow throughout the ring winding.
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 solution results in a more efficient and compact power module with even current distribution, reducing power consumption and enhancing the power density of data processing systems.
Implementation Method 1
a metal wiring layer, wherein the metal wiring layer is flat wound on a surface of at least one section of a magnetic column of the magnetic core
Implementation Method 2
forming a metal wiring layer on an outer side of the insulation layer through a metallization process
Data Source
AI summary
The present disclosure provides a magnetic element, a manufacturing method of a magnetic element, and a power module. The magnetic element includes: a magnetic core; and a metal wiring layer, where the metal wiring layer is flat wound on a surface of at least one section of a magnetic column of the magnetic core, the metal wiring layer includes a vertical portion and a horizontal portion, and at least part of the vertical portion forms a multi-turn metal winding by mechanically dividing.