Integrally Formed Inductor Structure for Low-Loss Inverse Coupling
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Solution Overview
Problem
Existing VRM inductors face challenges in achieving high power density, efficiency, and dynamic performance due to issues such as magnetic core saturation, eddy current loss, and inefficient winding paths, which hinder the integration of power connection components.
Innovation Solution
An integrally-formed inductor with a magnetic core and windings that are pressed together, featuring distributed air gaps and inverse coupling, allowing for pins on both surfaces and reduced winding path length, thereby minimizing eddy current loss and improving magnetic core utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the inductor uses a high-permeability magnetic material without air gap to increase inductance, then the inductance value increases, but the magnetic core becomes easy to saturate and has low utilization rate
Solution Approach 1:
The magnetic core is segmented into multiple magnetic substrates (first magnetic substrate, second magnetic substrate, third magnetic substrate, fourth magnetic substrate) arranged in series. This segmentation allows the magnetic flux to be distributed across multiple paths, increasing the overall inductance while preventing any single core from saturating, thus resolving the contradiction between high inductance and saturation resistance.
Solution Approach 2:
Different regions of the magnetic core structure are assigned different functions: the magnetic substrates provide high permeability for inductance, while the air gaps between substrates provide saturation resistance. The conductor portions are strategically placed to optimize both inductance generation and magnetic flux distribution, achieving local optimization of both contradictory requirements.
2Ease of operation
If the inductor uses an assembled structure of multiple magnetic substrates to achieve pins on both surfaces, then the pin arrangement requirement is met, but assembly gaps produce edge magnetic flux and eddy current loss
Solution Approach 1:
The magnetic substrates are merged through intimate contact with conductor portions embedded in the gaps between substrates. This merging eliminates the traditional assembly gap, preventing edge magnetic flux and eddy current loss while maintaining the pin arrangement capability on both upper and lower surfaces of the inductor.
Solution Approach 2:
Conductor portions serve as intermediaries between magnetic substrates, filling the gaps and providing both electrical connection and mechanical bonding. This intermediary structure eliminates the harmful assembly gaps while enabling the multi-surface pin configuration required for VRM integration.
3Adaptability or versatility
If the inductor winding extends from sides to top and bottom surfaces to achieve inverse coupling, then inverse coupling is realized, but the winding path becomes too long causing large DC loss
Solution Approach 1:
The winding structure transitions from a planar side-to-surface path to a three-dimensional path utilizing the vertical stacking of magnetic substrates. Conductor portions wind through the stacked substrate structure, achieving inverse coupling through vertical magnetic flux paths while significantly shortening the overall winding length and reducing DC loss.
4Ease of operation
If the inductor uses a traditional assembled structure to meet pin requirements, then pins can be disposed on upper and lower surfaces, but the structure is not easy to implement inverse coupling
Solution Approach 1:
The magnetic substrates and conductor portions are merged into an integrated structure where conductor portions are embedded within the magnetic core assembly. This merging simplifies the inverse coupling implementation by providing direct magnetic coupling paths through the stacked substrate structure, while maintaining pin disposition capability on upper and lower surfaces.
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
The solution enhances efficiency by reducing DC loss and eddy current loss, facilitates inverse coupling, and provides sufficient space for power and signal connection components, thus improving the overall performance of the VRM.
Implementation Method 1
a magnetic core and a first winding... The first winding includes a first longitudinal portion, a second longitudinal portion, and a first connecting portion being provided between the first longitudinal portion and the second longitudinal portion
Implementation Method 2
featuring distributed air gaps and inverse coupling, allowing for pins on both surfaces and reduced winding path length, thereby minimizing eddy current loss
Implementation Method 3
reduced winding path length, thereby minimizing eddy current loss and improving magnetic core utilization
Data Source
AI summary
An integrally-formed inductor includes a magnetic core and a first winding. The magnetic core includes a first surface and a second surface disposed opposite to each other, and a side surface disposed between the first surface and the second surface. The first winding includes a first longitudinal portion, a second longitudinal portion, and a first connecting portion provided between the first longitudinal portion and the second longitudinal portion. Wherein the first longitudinal portion extends to the first surface, forming a first pin. A projection of the first longitudinal portion on the first surface is within a range of the magnetic core. The second longitudinal portion extends to a plane where the second surface is positioned, and forms a second pin. The first winding and the magnetic core are integrally pressed by a mold to form the inductor.