Inverse-Coupled Inductor Layout for Compact Multi-Phase Power Modules
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Solution Overview
Problem
Conventional power modules with multi-phase inverse-coupled parallel connections have complex structures, large volume, tortuous winding lines, long output paths, poor heat dissipation, and inconvenient output pin arrangements, limiting their efficiency and dynamic performance.
Innovation Solution
A power module featuring an inverse-coupled inductor with linear windings and a magnetic core structure, combined with half-bridge modules, which simplifies the design, reduces output path length, and enhances heat dissipation, allowing for efficient multi-phase reverse-coupling and high power density.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If conventional multi-phase inverse-coupled parallel power modules are used, then power supply capability is achieved, but structure becomes complex and volume increases
Solution Approach 1:
The power module is divided into multiple independent phase units, each comprising a half-bridge circuit and corresponding inductor windings. Each phase can be independently designed and manufactured, then assembled together to form the complete multi-phase power module. This segmentation enables modular manufacturing and simplifies the overall structure while maintaining high power supply capability.
Solution Approach 2:
Multiple phase units are stacked vertically in a nested arrangement, with each phase occupying a different vertical layer. The inductor windings are arranged in inverse-coupled parallel configuration where phases are interleaved, allowing compact integration of multiple phases within a small footprint while reducing overall module volume.
2Power
If conventional power modules are used, then power delivery is achieved, but output path length increases and efficiency decreases
Solution Approach 1:
The output paths of different phases are arranged in the vertical dimension rather than extending horizontally. By stacking phases vertically and bringing output terminals close together in the vertical direction, the output path length is dramatically reduced, minimizing resistive losses and improving overall efficiency while maintaining full power delivery capability.
3Power
If conventional power modules are used, then power conversion is achieved, but heat dissipation performance deteriorates
Solution Approach 1:
Different regions of the power module are assigned different thermal management functions. The bottom surface features a large-area heat dissipation structure with high thermal conductivity material for efficient heat conduction. The side surfaces incorporate fin structures or heat sinks for convection cooling. This localized thermal management optimizes heat dissipation at each critical location while maintaining power conversion performance.
4Power
If conventional power modules are used, then power supply function is provided, but output pin arrangement becomes inconvenient
Solution Approach 1:
The output terminals are designed with a standardized universal arrangement that serves multiple functions: providing electrical connection, enabling thermal management, and facilitating easy integration with customer circuits. The terminal layout is optimized to be compatible with various application scenarios, making the power module easily adaptable to different customer designs while maintaining power supply functionality.
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
The solution enables improved efficiency, reduced volume, and enhanced dynamic performance by simplifying the structure, shortening output paths, and facilitating heat dissipation, while maintaining high power density and manufacturability.
Implementation Method 1
the inverse-coupled inductor includes: a plurality of windings and a magnetic core
Implementation Method 2
the magnetic core comprises a first magnetic core, a second magnetic core and a plurality of magnetic core pillars
Data Source
AI summary
The present disclosure relates to a power supply system including a power module. The power module includes an inverse-coupled inductor and a plurality of half-bridge modules. The inverse-coupled inductor includes: a plurality of windings and a magnetic core. The plurality of windings are linear windings between a first plane and a second plane. The first magnetic core and the second magnetic core are located at both ends of each of the windings, the magnetic core pillars connect the first magnetic core and the second magnetic core to form a plurality of magnetic core units, and the plurality of magnetic core units surround corresponding windings in a same direction from the first plane to the second plane. Projections of the plurality of magnetic core units on the first plane form a plurality of closed areas.