Magnetic Component Layout With Fillers for Higher Leakage Inductance

Solution Overview

Problem

Multi-phase trans-inductors in circuit architectures have insufficient leakage inductance, requiring an additional inductor in series, which increases manufacturing costs and occupies valuable space on a mainboard.

Innovation Solution

A magnetic component design featuring a core with first and second windings and magnetic fillers in specific filling regions between them, where the gap in the filling regions is larger than in non-filling regions, effectively increasing leakage inductance without increasing the component's height, thereby eliminating the need for an additional inductor.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If an additional inductor is connected in series to increase leakage inductance, then the leakage inductance is sufficient, but the manufacturing cost increases and board space is occupied

Engineering Contradiction:

Improveleakage inductanceVSAvoidcomponent quantity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent combines the function of increasing leakage inductance into the existing magnetic component structure by adding magnetic fillers between windings, merging multiple functions into a single component and eliminating the need for separate additional inductors

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent extracts the leakage inductance enhancement function from the external additional inductor and relocates it into the internal structure of the magnetic component through strategically placed magnetic fillers

Inventive Principle:

Principle #2Taking out (Extraction)

2Reliability

If an additional inductor is connected in series to increase leakage inductance, then the leakage inductance is sufficient, but the manufacturing cost increases

Engineering Contradiction:

Improveleakage inductanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent combines the function of increasing leakage inductance into the existing magnetic component structure by adding magnetic fillers between windings, merging multiple functions into a single component and eliminating the need for separate additional inductors

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The magnetic component is designed to perform multiple functions simultaneously - providing both the required inductance and the enhanced leakage inductance through integrated magnetic fillers, making the component universally applicable without additional parts

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Reliability

If an additional inductor is connected in series to increase leakage inductance, then the leakage inductance is sufficient, but the space on mainboard is occupied

Engineering Contradiction:

Improveleakage inductanceVSAvoidboard space

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent combines the function of increasing leakage inductance into the existing magnetic component structure by adding magnetic fillers between windings, merging multiple functions into a single component and eliminating the need for separate additional inductors

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The magnetic fillers are nested within the existing magnetic component structure between the windings, utilizing the internal space of the component to achieve leakage inductance enhancement without increasing external dimensions

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 design enhances leakage inductance in magnetic components, reducing manufacturing costs and board space requirements by integrating magnetic fillers between windings, allowing for sufficient inductance in DC-to-DC converters without additional inductors.

Implementation Method 1

At least one filling region and at least one non-filling region are formed between the first winding and the second winding. The at least one magnetic filler is filled in at least a part of the at least one filling region

Methodology Applied

Scientific EffectMagnetic reluctance: Magnetic Reluctance

Data Source

PatentUS20240428978A1Magnetic component

Publication Date: 2024.12.26 CYNTEC

AI summary

A magnetic component includes a core, a first winding, a second winding and at least one magnetic filler. The core includes an inner leg. The first winding is disposed in the core and wound around the inner leg. The second winding is disposed in the core and surrounds the first winding. At least one filling region and at least one non-filling region are formed between the first winding and the second winding. The at least one magnetic filler is filled in at least a part of the at least one filling region.