Integrated Magnetic Assembly With Multi-Component Core for Compact Inductance

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Solution Overview

Problem

Existing integrated magnetic assemblies face challenges in achieving high power density while minimizing size, as increased frequencies lead to material losses and larger inductors, and series connections increase reliability risks and physical space requirements.

Innovation Solution

The integration of multiple inductors into a single structure with a center core component and two outer core components, forming channels for winding and connection legs, which reduces the number of solder joints and optimizes physical space, enhancing power density and reliability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Power

If frequencies are increased, then power density is improved, but core losses increase and limit material selection

Engineering Contradiction:

Improvepower densityVSAvoidcore losses

Core Design Contradiction:

PowerVSLoss of energy

Solution Approach 1:

The magnetic core is divided into multiple separate core components (first core component, second core component, center core component) that are coupled together. This segmentation allows each core component to operate at lower individual flux densities, reducing core losses while maintaining the overall power density through the multi-turn winding configuration.

Inventive Principle:

Principle #1Segmentation

2Power

If lower frequencies are used, then inductance values increase, but inductor physical size increases

Engineering Contradiction:

Improveinductance valueVSAvoidinductor size

Core Design Contradiction:

PowerVSVolume of moving object

Solution Approach 1:

Multiple core components are merged into a single integrated magnetic assembly with a shared winding structure. The first and second core components are coupled to the center core component, forming a unified magnetic circuit that achieves high inductance values in a compact footprint through the combined magnetic paths.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The magnetic assembly utilizes three-dimensional spatial arrangement with core components positioned at different locations (first core component, center core component, second core component) and winding legs extending through multiple channels. This dimensional optimization allows high inductance to be achieved without proportionally increasing the overall footprint.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

3Power

If multiple inductors are connected in series, then inductance requirements are met, but reliability decreases due to multiple solder joints

Engineering Contradiction:

Improveinductance requirementVSAvoidreliability

Core Design Contradiction:

PowerVSReliability

Solution Approach 1:

Multiple inductor functions are merged into a single integrated magnetic assembly where the winding is continuously coupled to multiple core components. This eliminates the need for separate solder joints between discrete inductors, as the magnetic components are mechanically and magnetically coupled in a unified structure, thereby improving reliability.

Inventive Principle:

Principle #5Merging (Combining)

4Power

If multiple inductors are connected in series, then inductance requirements are met, but physical space increases

Engineering Contradiction:

Improveinductance requirementVSAvoidfootprint

Core Design Contradiction:

PowerVSArea of stationary object

Solution Approach 1:

The magnetic core components are nested or closely coupled together in a compact arrangement. The center core component is positioned between the first and second core components, with winding legs extending through defined channels. This nested configuration allows multiple inductor functions to occupy overlapping or adjacent spatial regions, minimizing the overall footprint while meeting inductance requirements.

Inventive Principle:

Principle #7Nested doll (Nesting)

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 configuration increases power density and reduces the size of the magnetic assembly, improving reliability by minimizing solder joints and optimizing space usage, while maintaining efficient current and flux flow.

Implementation Method 1

a winding including a pair of winding plates, a pair of winding legs extending from a first end of the pair of winding plates

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

a first core component including a first plurality of legs extending from a first inner face, a second core component including a second plurality of legs extending from a second inner face

Methodology Applied

Scientific EffectFerromagnetism: Ferromagnetism

Data Source

PatentUS20240249872A1Integrated magentic assembly including a multi turn inductor on a multi-component core

Publication Date: 2024.07.25 OMNION POWER TECHNOLOGY GMBH

AI summary

An integrated magnetic assembly includes a first core component, a second core component, and a center core component. The center core component is located between and is coupled to the first and second core components. A winding including a pair of winding plates, a pair of winding legs extending from a first end of the pair of winding plates, a pair of connection legs extending from a second end of the pair of winding plates, and a connection tab joining the connection legs. The first core component and the center core component are coupled, defining at least two first channels, and the second core component and the center core component are coupled, defining at least two second channels. Each of the winding legs and each of the connection legs are located in one of the two first channels or one of the two second channels.