Integrated Inductor Conductors for Larger Power Module Magnetics
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Solution Overview
Problem
Existing power module designs are limited by inefficient electrical connections and mechanical support structures, which restrict inductor size and thermal performance, particularly in high-power density applications.
Innovation Solution
An inductor core with integrated conductors that span multiple surfaces, providing both electrical and thermal conductivity, eliminating the need for external connector boxes and side structures, and allowing for maximized inductor size within a given form factor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a PCB or connector box is used to build electrical connections and provide mechanical support, then mechanical support and electrical connections are provided, but the inductor size is limited and thermal performance is reduced
Solution Approach 1:
The patent merges the functions of the inductor core, electrical connections, and mechanical support into a single integrated structure. The inductor core itself is designed to provide mechanical support and electrical connections through integrated conductors, eliminating the need for separate PCB or connector box structures. This consolidation removes the constraints that previously limited inductor size and thermal performance.
2Temperature
If a PCB or connector box is used to build electrical connections, then electrical connections are provided, but thermal performance is limited
Solution Approach 1:
The patent combines thermal management functions directly into the inductor core structure. The integrated conductors within the inductor core serve as thermal pathways, allowing heat to be conducted efficiently from the power devices to the heat sink or cooling structures. This eliminates the thermal limitations imposed by separate PCB or connector box designs.
3Ease of manufacture
If external connector boxes and side structures are used, then mechanical support is provided, but production costs increase
Solution Approach 1:
The patent consolidates multiple components into a single integrated inductor core structure that provides mechanical support, electrical connections, and thermal management functions. This reduces the number of parts that need to be manufactured and assembled, thereby lowering production costs while eliminating the complexity of external connector boxes and side structures.
4Volume of moving object
If integrated conductors are used, then inductor size is maximized and thermal performance is enhanced, but manufacturing complexity increases
Solution Approach 1:
The conductors are integrated into the inductor core during the manufacturing process itself, rather than being added as separate components. This preliminary integration allows the conductors to be positioned and secured within the core structure before final assembly, simplifying the overall manufacturing process despite the increased complexity of the integrated design.
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 enhances thermal performance, reduces device size, and potentially lowers production costs by integrating conductors directly into the inductor core, providing robust electrical connections and optimal heat dissipation.
Implementation Method 1
an inductor winding disposed at least partially within the inductor core volume, the inductor winding and the inductor core forming an inductor
Implementation Method 2
a subset of the plurality of conductors is at least one of an electrical conductor and a thermal conductor
Data Source
AI summary
According to an example, a structure is generally described. The structure may include an inductor core having a plurality of surfaces; and at least one conductor integrated with at least one surface of the plurality of surfaces of the inductor core.