Inductor Conductive Standoffs for Core Crack Resistance
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Solution Overview
Problem
Inductors in power conversion circuitry are prone to failure under mechanical stress due to their large size and the use of ferrite magnetic cores, which are susceptible to cracking, limiting their integration in high-density applications.
Innovation Solution
The integration of electrically conductive standoffs that extend along the magnetic core sides to transfer mechanical forces between substrates, isolating the magnetic core and preventing cracking, while also enabling high-density integration and heat management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If inductors are made large to store sufficient energy and prevent magnetic saturation, then energy storage capability is improved, but mechanical stress resistance deteriorates due to susceptibility to cracking
Solution Approach 1:
The patent introduces a stress transfer member (electrically conductive standoff) as an intermediary between the inductor and substrate. This mediator absorbs and transfers mechanical stress away from the inductor body, allowing the inductor to maintain large size for energy storage while the stress transfer member handles the mechanical load, preventing cracking and improving reliability
Solution Approach 2:
The patent segments the mechanical stress path from the inductor structure by introducing separate stress transfer members. The inductor is divided into functional segments: the magnetic core for energy storage and the stress transfer members for mechanical load bearing, allowing each to optimize its primary function without compromising the other
2Use of energy by moving object
If inductors are made large to prevent magnetic saturation, then magnetic performance is improved, but device density deteriorates due to increased size
Solution Approach 1:
The patent moves the stress transfer function to a separate dimensional element (vertical standoffs extending from substrate to inductor) rather than increasing horizontal inductor dimensions. This allows the inductor to maintain compact footprint for high density while adding vertical dimension for stress management, enabling large magnetic core volume without proportionally increasing overall device footprint
3Productivity
If inductors are integrated between substrates for high-density applications, then device integration is improved, but mechanical stress on inductors increases causing cracking
Solution Approach 1:
The electrically conductive standoff serves as a mediator between the inductor and substrates, providing a dedicated stress transfer path that isolates the inductor from direct mechanical contact with substrates. This allows high-density integration between substrates while the standoff absorbs and distributes mechanical stress, preventing inductor cracking and maintaining reliability
Solution Approach 2:
The patent replaces direct mechanical contact between inductor and substrates with an intermediary stress transfer system. Instead of the inductor directly bearing mechanical loads from substrate mounting, the electrically conductive standoffs substitute as the mechanical load-bearing elements, transferring stress away from the inductor's magnetic core and winding structure
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 allows for the sandwiching of inductors between substrates, enhancing power conversion circuitry density and protecting the magnetic core from mechanical damage, while facilitating heat transfer and electrical coupling between substrates.
Implementation Method 1
electrically conductive standoffs that extend along the magnetic core sides to transfer mechanical forces between substrates
Implementation Method 2
Each of the standoffs may be electrically connected to a respective winding and/or substrate
Implementation Method 3
An inductor typically includes a magnetic core, such as formed of a ferrite magnetic material, and one or more windings wound around at least a portion of the magnetic core
Data Source
AI summary
An inductor includes a magnetic core, a first winding, a first electrically conductive standoff, and a second electrically conductive standoff. The magnetic core includes opposing first and second outer surfaces separated from each other in a first direction. The first winding has first and second ends, and the first winding is wound around at least a portion of the magnetic core. The first electrically conductive standoff is connected to the first end of the first winding, and the first electrically conductive standoff extends along the magnetic core in the first direction from the first outer surface to the second outer surface. The second electrically conductive standoff is connected to the second end of the first winding, and the second electrically conductive standoff extends along the magnetic core in the first direction from the first outer surface to the second outer surface.