Magnetic Component with Shielding Protrusion for VRM Loss Reduction
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Solution Overview
Problem
Voltage regulator modules (VRMs) face high winding loss and magnetic leakage flux issues due to increasing operation speeds and currents in data centers and AI applications, which affect power density, efficiency, and dynamic performance.
Innovation Solution
A magnetic component design featuring a first magnetic pole with an air gap, a cover plate, a protrusion surrounding the pole, and a winding with a lead supported by the protrusion to create a clearance between the winding and the pole, optimizing the magnetic core utilization and reducing fringe magnetic flux.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the winding is placed close to the magnetic pole to increase power density, then the power density is improved, but the winding loss increases due to magnetic leakage flux and eddy-current loss
Solution Approach 1:
The patent introduces a magnetic shielding layer (intermediary) between the winding and the magnetic pole. This shielding layer redirects the magnetic leakage flux, preventing it from directly interacting with the winding conductors. As a result, the winding can remain close to the magnetic pole for high power density while the shielding layer absorbs and redirects the harmful magnetic flux, reducing eddy-current loss and winding loss.
2Reliability
If the winding is placed close to the magnetic pole to improve circuit efficiency, then the inductance is improved, but the magnetic leakage flux interferes with other elements and devices
Solution Approach 1:
The magnetic shielding layer acts as an intermediary that contains and redirects magnetic leakage flux. By positioning this shielding layer between the magnetic pole and surrounding elements, the flux is confined and redirected along controlled paths, preventing interference with nearby electronic components and devices while maintaining the close coupling needed for high circuit efficiency.
Solution Approach 2:
The patent extracts the harmful magnetic leakage flux from the main magnetic circuit by introducing the shielding layer. The shielding layer creates separate flux paths that isolate the leakage flux from sensitive areas, effectively removing its harmful effects while preserving the beneficial magnetic coupling between the winding and magnetic pole.
3Device complexity
If the winding is supported directly on the magnetic pole to simplify structure, then the device complexity is reduced, but the eddy-current loss increases
Solution Approach 1:
The magnetic shielding layer serves as an intermediary support structure between the winding and the magnetic pole. Instead of directly mounting the winding on the magnetic pole (which causes eddy-current loss), the shielding layer provides mechanical support while electrically and magnetically isolating the winding from the pole, thereby reducing eddy-current loss without significantly increasing structural complexity.
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 circuit efficiency by minimizing winding loss, reducing eddy-current loss, and simplifying production while maintaining low costs and flexible interconnection with power modules.
Implementation Method 1
a first magnetic pole extending in a first direction and having an air gap provided therein
Implementation Method 2
a winding surrounding the first magnetic pole at the air gap and having a lead supported by the protrusion such that a clearance is formed between the winding and the first magnetic pole
Data Source
AI summary
There is disclosed a magnetic component which includes a first magnetic pole extending in a first direction and having an air gap provided therein, a second magnetic pole extending in the first direction, a cover plate extending in a second direction perpendicular to the first direction and connected with an end of the first magnetic pole and an end of the second magnetic pole, a protrusion formed on and at least partially surrounding the first magnetic pole, and a winding wound around the first magnetic pole at the air gap and having a lead supported by the protrusions such that a clearance is formed between the winding and the first magnetic pole.