Integrated Multi-Phase Power Inductor with Non-Coupled Windings
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Solution Overview
Problem
Existing integrated multi-phase power inductors face challenges such as inductance unbalance, high manufacturing costs due to complex assembly, limited saturation current performance, and high alternating current resistance caused by fringing effects, which hinder their effectiveness in higher power and current applications.
Innovation Solution
A single piece magnetic core with distributed gap material and three-dimensional conductive windings is used, eliminating the need for bonding discrete core pieces and reducing fringing flux, while the taller profile and smaller footprint accommodate higher power and current demands.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple discrete core pieces are bonded together to form an integrated multi-phase power inductor, then the inductance balance between phases is improved, but the manufacturing complexity and assembly difficulty increase
Solution Approach 1:
The patent merges multiple discrete core pieces into a single integrated core structure with multiple interior passageways. This single core piece contains all necessary magnetic paths and windings, eliminating the need to bond separate core pieces together. The integration maintains inductance balance through symmetric design while significantly reducing assembly complexity and manufacturing steps.
Solution Approach 2:
The single core piece is segmented into multiple interior passageways, each accommodating a separate winding for different phases. This segmentation allows independent optimization of each phase while maintaining overall integration, achieving both inductance balance and simplified assembly.
2Adaptability or versatility
If discrete core pieces are bonded together to create integrated inductors, then multi-phase power regulation is achieved, but the manufacturing cost increases
Solution Approach 1:
The patent combines multiple core pieces into one integrated structure that provides multi-phase power regulation capabilities. This merging eliminates the need for separate inductor components for each phase, reducing part count, assembly operations, and manufacturing costs while maintaining full multi-phase functionality.
Solution Approach 2:
The single core piece serves multiple functions simultaneously by providing magnetic paths for multiple phases within one component. This universal design achieves multi-phase power regulation without requiring separate discrete inductors, thereby reducing manufacturing complexity and cost.
3Area of stationary object
If traditional core structures are used in integrated inductors, then space savings are achieved, but saturation current performance is limited
Solution Approach 1:
The patent transitions from planar core structures to a three-dimensional single piece core with vertical interior passageways. This dimensional change allows windings to be positioned in multiple levels and orientations, increasing the effective magnetic path length and saturation current capacity without increasing the planar footprint on the circuit board.
Solution Approach 2:
The core structure employs nested interior passageways where windings are positioned within cavities and channels of the three-dimensional core. This nesting arrangement maximizes the use of available space, allowing multiple windings to be accommodated in a compact volume while maintaining high saturation current performance.
4Ease of manufacture
If conventional inductor designs are used, then manufacturing is simpler, but alternating current resistance is high due to fringing effects
Solution Approach 1:
The patent implements distributed gap material specifically at critical locations within the core structure where fringing flux occurs. This localized application of gap material controls and distributes the magnetic flux more evenly, reducing fringing effects and alternating current resistance without requiring a complete redesign of the manufacturing process.
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 simplifies assembly, reduces manufacturing costs, achieves balanced inductance, and enhances saturation current performance, providing higher power capability with reduced alternating current resistance.
Implementation Method 1
Power inductors are designed to induce magnetic fields via current flowing through one or more conductive windings, and store energy via the generation of magnetic fields in magnetic cores associated with the windings
Implementation Method 2
store energy via the generation of magnetic fields in magnetic cores associated with the windings
Implementation Method 3
Power inductors also return the stored energy to the associated electrical circuit by inducing current flow through the windings
Data Source
AI summary
A surface mount power inductor component for a circuit board including multi-phase power supply circuitry includes a single piece, integrally fabricated magnetic core piece formed with vertically extending interior passageways provided with vertically elongated pre-formed conductive windings that are not magnetically coupled to reduce the footprint of the inductor component while increasing its power capacity. A distributed gap material is also provided in the vertical passageways with the conductive windings that respectively connect to each phase of electrical power.