Inverse-Coupled Inductor Structure 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 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 power modules use multi-phase inverse-coupled parallel connections, then power supply capability is improved, but structure complexity increases and volume increases
Solution Approach 1:
The inductor is divided into multiple independent winding units (first winding unit, second winding unit, third winding unit, fourth winding unit) with separate magnetic cores. Each winding unit can be independently designed and manufactured, simplifying the overall structure while enabling multi-phase power supply capability. The segmentation allows for modular assembly and reduces structural complexity.
Solution Approach 2:
The patent transitions from planar windings to three-dimensional vertical windings that extend along the height direction of the magnetic cores. This dimensional change enables compact stacking of multiple winding units, achieving high power density without increasing footprint area, and simplifies the connection structure by utilizing vertical space efficiently.
2Power
If conventional power modules use multi-phase inverse-coupled parallel connections, then power supply capability is improved, but winding path length increases and efficiency decreases
Solution Approach 1:
By segmenting the inductor into multiple independent winding units with separate magnetic cores, each winding has a dedicated and optimized magnetic path. This eliminates the need for long inter-winding connections and reduces the overall winding path length, thereby minimizing resistive losses and improving efficiency.
Solution Approach 2:
The patent merges the magnetic paths of multiple windings into vertically stacked magnetic core units that share common magnetic flux paths in the height direction. This merging approach shortens the effective magnetic path length and reduces the winding path length required, improving efficiency while maintaining multi-phase power supply capability.
3Power
If conventional power modules use multi-phase inverse-coupled parallel connections, then power supply capability is improved, but heat dissipation performance worsens
Solution Approach 1:
The patent utilizes the vertical dimension by stacking magnetic cores and winding units along the height direction. This three-dimensional arrangement creates vertical heat dissipation pathways, allowing heat to be conducted upward through the magnetic cores and dissipated more effectively, overcoming the limited horizontal heat dissipation area in conventional planar designs.
Solution Approach 2:
By dividing the inductor into multiple independent winding units with separate magnetic cores, each unit can be independently thermally managed. The segmentation creates multiple heat dissipation channels and reduces thermal coupling between phases, improving overall heat dissipation performance while maintaining high power supply capability.
4Power
If conventional power modules use multi-phase inverse-coupled parallel connections, then power supply capability is improved, but output path length increases and volume increases
Solution Approach 1:
The patent employs vertical stacking of magnetic cores and winding units along the height direction, transforming the layout from horizontal expansion to vertical development. This dimensional change achieves high power supply capability within a compact footprint, significantly reducing the overall volume while maintaining multi-phase power supply function.
Solution Approach 2:
Multiple winding units and magnetic cores are merged into a vertically integrated structure where components share common mounting spaces and connection points. This merging approach consolidates the multi-phase power supply system into a compact unit, reducing volume while improving power density.
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 with better heat dissipation and manufacturability, achieving high power density and reduced ripple current while maintaining compactness.
Implementation Method 1
the inverse-coupled inductor includes: a plurality of windings and a magnetic core
Data Source
AI summary
The present disclosure relates to a multi-phase inverse-coupled inductor. The multi-phase inverse-coupled inductor includes two windings and a magnetic core. The magnetic core includes a first magnetic core, a second magnetic core, and a plurality of magnetic core pillars. The first magnetic core and the second magnetic core are located at both ends of each of the windings, respectively; the magnetic core pillars connect the first magnetic core and the second magnetic core to form two magnetic core units, and the magnetic core units are disposed to be in a one-to-one correspondence with the windings.