Integrated Coupled Inductor Structure for High-Coupling Voltage Regulation
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Solution Overview
Problem
Existing coupled inductors have low inductive coupling due to incomplete contact between the magnetic core and conductive coils, leading to low power density and inadequate heat dissipation.
Innovation Solution
An integrated inductor design where an inner conductive coil is inserted through an outer conductive coil, both of which are embedded in a magnetic core using an integrated molding process, ensuring full contact and high coupling efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional assembled inductors are used with ferrite magnetic cores and conductive coils, then the structure is simple to manufacture, but the inductive coupling is low and power density is insufficient
Solution Approach 1:
The patent merges the magnetic core and conductive coils into a single integrated inductor component. The first and second conductive coils are embedded directly within the magnetic core, forming an integrated structure that eliminates the need for separate assembly of these components. This integration achieves full contact between the coils and magnetic core, resulting in a coupling coefficient of 0.98 or above, while maintaining manufacturing feasibility through a unified construction approach.
2Power
If assembled inductors are used with separate magnetic core and conductive coils, then the manufacturing process is simple, but the contact between components is incomplete leading to low power density
Solution Approach 1:
The patent combines the magnetic core and multiple conductive coils into a single integrated component where the coils are embedded within the magnetic core material. This merging creates full contact between all components, eliminating air gaps and improving coupling efficiency to achieve a coupling coefficient of 0.98 or above, thereby significantly increasing power density while maintaining manufacturing simplicity through integrated construction.
Solution Approach 2:
The patent implements a nested structure where the first and second conductive coils are embedded within the magnetic core. The coils are positioned inside the magnetic core material, with the first coil potentially nested within or adjacent to the second coil, creating a compact integrated arrangement that maximizes contact area and coupling efficiency while maintaining a unified component structure.
3Temperature
If assembled inductors are used with separate components, then the structure is easier to assemble, but heat dissipation is insufficient due to poor thermal contact
Solution Approach 1:
The patent merges the magnetic core and conductive coils into an integrated structure where the coils are embedded within the magnetic core material. This integration creates direct thermal contact between the coils and magnetic core, eliminating air gaps that impede heat transfer. The unified construction enables efficient heat dissipation pathways from the coils through the magnetic core, reducing operating temperature while maintaining structural simplicity.
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
Achieves a high coupling coefficient of 0.98 or above, resulting in fast response times and reduced power loss, while also improving heat dissipation and maintaining a lower operating temperature.
Implementation Method 1
The inner conductive coil and the outer conductive coil are insulated from each other; the inner conductive coil rans through the outer conductive coil whereby most of or all magnetic field lines of the inner conductive coil pass through the outer conductive coil
Implementation Method 2
The magnetic core and conductive coils cannot be in full contact in the assembled inductor, the power density is low, and the heat dissipation is insufficient
Data Source
AI summary
An 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 an inner conductive coil and an outer conductive coil coupled to the inner conductive coil. The inner conductive coil and the outer conductive coil are insulated from each other; the inner conductive coil rans through the outer conductive coil whereby most of or all magnetic field lines of the inner conductive coil pass through the outer conductive coil. A trans-inductor voltage regulator provided, includes a circuit board and the inductor electrically connected to the circuit board. The inductor has a coupling coefficient more than 98%.