Integrated Magnetic Composite Substrate for Power Converter Modules

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Solution Overview

Problem

Conventional power converter modules are limited in size due to the need to accommodate both magnetic components and electrical connections, leading to reduced power transmission capacity and efficiency.

Innovation Solution

The magnetic device assembly maximizes the size of magnetic components by co-locating and sharing input, output, and auxiliary terminals between substrates, allowing the magnetic components to extend to the full extent of the power converter module, thereby increasing power throughput and efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If magnetic components are shrunk to fit within the power converter module extents, then the components can be integrated within the module, but the power transmission capacity and efficiency are reduced

Engineering Contradiction:

Improveintegration capabilityVSAvoidpower transmission capacity

Core Design Contradiction:

Adaptability or versatilityVSPower

Solution Approach 1:

The patent transitions from a two-dimensional planar layout to a three-dimensional stacked configuration. The magnetic substrate is positioned vertically above the power converter substrate, allowing magnetic components to extend in the Z-dimension rather than being constrained to the XY-plane. This dimensional change enables both substrates to occupy the same footprint area while maintaining full functionality of both power conversion and magnetic operations at maximum power levels.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The shared terminal structure serves multiple functions simultaneously: it provides electrical connections for both the power converter substrate and the magnetic substrate, acts as a mechanical support structure, and enables thermal management pathways. The terminals are designed to accommodate both substrates' connection requirements through a unified interface, eliminating the need for separate connection structures.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Ease of manufacture

If additional space is reserved for electrical connections within the reduced area, then connections can be accommodated, but the size of magnetic components is further reduced

Engineering Contradiction:

Improveconnection accommodationVSAvoidmagnetic component size

Core Design Contradiction:

Ease of manufactureVSArea of moving object

Solution Approach 1:

The patent merges the electrical connection functions of both substrates into a single shared terminal structure. Instead of providing separate terminals for the power converter substrate and the magnetic substrate, the design uses one set of terminals that serve both substrates simultaneously. This consolidation eliminates redundant connection structures and maximizes the area available for magnetic components.

Inventive Principle:

Principle #5Merging (Combining)

3Adaptability or versatility

If magnetic components are reduced in size to fit within smaller allocated area, then integration is achieved, but power rating and efficiency are compromised

Engineering Contradiction:

Improveintegration capabilityVSAvoidpower rating

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent utilizes the vertical dimension to accommodate magnetic components at full size. By stacking the magnetic substrate above the power converter substrate, the magnetic components can extend vertically without occupying additional horizontal space. This enables the magnetic components to maintain their full power rating and efficiency while achieving integration within the module.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 approach enables a higher power rating and greater efficiency by maximizing the size of magnetic components within the power converter module, allowing for increased power transmission without the need to shrink magnetic components for electrical connections.

Implementation Method 1

at least one co-located power and integrated terminal is interconnected by a dual directed terminal, wherein each dual directed terminal includes a central portion extending between a distal end and a terminus end; a conductive element wrapped along a portion of the central portion

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS10141856B2Integrated magnetic and composite substrate with incorporated components

Publication Date: 2018.11.27 EICHER HAROLD

AI summary

A magnetic device assembly is provided for maximizing the size of the magnetic components for a predetermined power converter module by co-locating and sharing input, output, and auxiliary terminals between the substrates for the power converter and the magnetic components. Wherein complete power module is the result of constructing the separate constituent parts which include an integrated magnetic substrate, magnetic elements mounted therein, a power converter substrate, associated incorporated components located top and bottom on the power converter substrate, a composite mechanical footprint as defined by the mechanical extents of the integrated magnetic substrate and power converter substrate, and a composite electrical pinout as defined by the input-output pins which are coincident to and co-located as those of the integrated magnetic and power converter substrates.