Magnetic Component with Horizontal Flux and Pre-formed Windings
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Solution Overview
Problem
Conventional inverse-coupled-inductor modules have a high profile height, which is not suitable for applications with strict height requirements, and their magnetic flux distribution is uneven, leading to inefficiencies in power density and dynamic performance in voltage regulating modules.
Innovation Solution
A magnetic component with a monolithic magnetic core and pre-formed winding sets, where the winding sets are disposed on the magnetic core without overlapping air gaps, allowing for a low profile design with reduced thermal resistance and simplified manufacturing process, and the use of magnetic powder material for improved dimensional accuracy and reduced production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a conventional inverse-coupled-inductor module is adopted to reduce inductor volume and improve efficiency, then the power density and dynamic performance are improved, but the profile height becomes too large for applications with strict height requirements
Solution Approach 1:
The patent transitions from a vertical magnetic flux structure to a horizontal magnetic flux structure, changing the orientation of the magnetic flux plane from vertical to parallel with the pin plane. This dimensional reorientation allows the magnetic flux to flow horizontally through the magnetic core, significantly reducing the profile height while maintaining the coupled inductor functionality and power density improvements.
Solution Approach 2:
The magnetic core is divided into multiple segments (first magnetic core, second magnetic core, third magnetic core) arranged horizontally, with each segment contributing to the magnetic flux path. This segmentation allows the magnetic flux to distribute across multiple horizontal paths, reducing the height requirement while maintaining the necessary inductance and coupling characteristics.
2Length of stationary object
If a horizontal magnetic flux structure is adopted to reduce overall height, then the profile height is reduced, but the footprint area becomes larger and magnetic flux distribution becomes very uneven
Solution Approach 1:
The patent introduces magnetic flux concentration structures (such as magnetic flux guides or optimized core geometries) at specific locations within the horizontal magnetic flux path. These local modifications concentrate and evenly distribute the magnetic flux across the horizontal plane, preventing flux concentration in specific areas and ensuring uniform flux distribution throughout the magnetic core structure, thereby reducing the required footprint area.
3Ease of manufacture
If winding sets are bent together with the magnetic core during assembly, then the components can be combined, but the magnetic core may be damaged and the manufacturing process becomes complex
Solution Approach 1:
The winding sets are pre-formed and pre-assembled onto the magnetic core in a controlled manufacturing process before final assembly. This preliminary action allows the windings to be positioned and secured while the magnetic core is in its optimal state, avoiding the need to bend or deform the magnetic core during assembly. The pre-assembly process ensures proper alignment and reduces the risk of damaging the magnetic core, thereby maintaining reliability while simplifying the overall 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
The solution results in a magnetic component with reduced overall height, lower thermal resistance, and improved structural strength, while also simplifying the manufacturing process and reducing production costs, making it suitable for high-performance applications in voltage regulating modules.
Implementation Method 1
The magnetic core and the two winding sets form a magnetic component... The first winding set and the second winding set are disposed on the first magnetic column of the magnetic core
Data Source
AI summary
A magnetic component and a manufacturing method thereof are provided. The magnetic component includes a magnetic core, a first winding set and a second winding set. The magnetic core is made of a magnetic powder material and includes two connecting portions connected through three magnetic columns to form a first side and a second side opposite to each other. The first winding set and the second winding set are made by a flat conductive body, and spaced apart on the middle magnetic column at a distance. The first winding set includes two first conducting portions connected through a first horizontal portion. The second winding set includes two second conducting portions connected through a second horizontal portion. The first horizontal portion and the second horizontal portion are exposed to the first side, and the two first conducting portions and the two second conducting portions are extended to the second side.