Integrated Coupled Inductor Layout for High-Density Voltage Regulators
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Solution Overview
Problem
Traditional coupled and integrated inductors face challenges such as large size, low power density, temperature rise, and low coupling coefficient, making them inadequate for high-frequency, high-power-density, and small-sized electronic applications.
Innovation Solution
A coupled and integrated inductor design featuring a magnetic core with one or more conductive coil assemblies, where each coil assembly consists of a first and second conductive coil coupled together, sharing a magnetic path and being closely fitted side by side within the magnetic core, achieving a high coupling coefficient of over 0.92.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional coupled inductors or integrated inductors are used, then the basic inductor function is achieved, but the size is large, power density is low, temperature rises, and coupling coefficient is low
Solution Approach 1:
The patent merges multiple coils into a single integrated inductor structure with a shared magnetic core. The first and second conductive coils are wound around the same magnetic core, creating a compact coupled inductor structure that achieves high coupling coefficient while reducing overall size compared to traditional separate inductor designs.
Solution Approach 2:
The patent employs a nested structure where the first and second conductive coils are arranged concentrically or adjacently around the same magnetic core. This nesting approach allows the coils to share the same spatial envelope, significantly reducing the volume required while maintaining high magnetic coupling between the coils.
2Reliability
If traditional coupled inductors or integrated inductors are used, then the basic inductor function is achieved, but the size is large, power density is low, temperature rises, and coupling coefficient is low
Solution Approach 1:
The patent combines multiple functional coils into a single integrated structure sharing a common magnetic core, thereby increasing the power handling capability per unit volume. This merging of functions into a compact structure directly improves power density while maintaining or enhancing reliability.
Solution Approach 2:
The patent optimizes geometric parameters such as coil winding density, turn ratios, and magnetic core dimensions to maximize power density. By carefully controlling these parameters, the inductor achieves higher power handling capability in a reduced volume while maintaining acceptable temperature rise characteristics.
3Reliability
If traditional coupled inductors or integrated inductors are used, then the basic inductor function is achieved, but temperature rise occurs due to inefficiency
Solution Approach 1:
The patent merges the magnetic paths of multiple coils into a shared core structure, which reduces magnetic leakage and improves coupling efficiency. This reduced energy loss translates to lower temperature rise, improving the inductor's ability to maintain reliable operation under thermal constraints.
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 proposed inductor design achieves a high coupling coefficient, improved magnetic permeability and flux density, reduced power loss, effective heat dissipation, and a compact, high-density structure, addressing the limitations of traditional inductors.
Implementation Method 1
An inductor is a component that can convert electrical energy into magnetic energy and store it
Implementation Method 2
It generally consists of a magnetic core, one or more conductive coils
Data Source
AI summary
A coupled and integrated inductor provided in the present invention, includes a magnetic core and one or more conductive coil assembly embedded in the magnetic core; each conductive coil assembly comprises a first conductive coil and a second conductive coil coupled to the first conductive coil. The magnetic core is in close contact with both the first conductive coil and the second conductive coil; the first conductive coil and the second conductive coil pass through the magnetic core side by side, parallel and in close contact with each other, and the first conductive coil and the second conductive coil share a magnetic path. A trans-inductor voltage regulator provided, includes a circuit board and the coupled and integrated inductor electrically connected to the circuit board. The inductor has a coupling coefficient more than 92%, which improves the overall performance of the coupled and integrated inductor.