Magnetic Element Segmentation for PCB Space Utilization
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Solution Overview
Problem
In modular server and networking power supplies, the limited height of the modular circuit board restricts the utilization of space, particularly around the resonant inductor magnetic post, leading to inefficiencies in power component placement and increased volume, weight, and power loss due to the design of traditional magnetic elements.
Innovation Solution
A magnetic element design featuring a main body with strategically arranged first and second magnetic posts, a common magnetic post, and a second magnetic post, allowing for enhanced PCB utilization by optimizing the arrangement of magnetic components and winding structures to maximize space usage on the circuit board.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional magnetic element design is used with resonant inductor magnetic post and transformer magnetic post arranged side by side, then the magnetic element can be manufactured with automated PCB winding, but the space between the resonant inductor magnetic post and the edge of the modular circuit board cannot be utilized, leading to low PCB utilization
Solution Approach 1:
The magnetic element is segmented into multiple magnetic posts (first magnetic posts for resonant inductor, second magnetic post for transformer, and third magnetic post for output inductor) arranged in different directions. This segmentation allows each magnetic post to serve its specific function while enabling independent optimization of space utilization around each post, thereby resolving the contradiction between automated manufacturability and PCB space utilization.
Solution Approach 2:
The invention transitions from a traditional side-by-side arrangement of magnetic posts along one direction to a multi-dimensional arrangement where magnetic posts are distributed along both the first direction (for automated winding) and the second direction (for space utilization). This dimensional expansion allows the third magnetic post to be positioned near the second lateral edge, enabling effective use of previously wasted PCB space while maintaining automated manufacturability.
2Power
If the height of the modular circuit board is limited to 1 U, then the power density can be increased, but the volume of the magnetic element takes up a great proportion of the modular circuit board, restricting component placement options
Solution Approach 1:
The magnetic element employs local quality by assigning different functions to different magnetic posts and their surrounding spaces. The first magnetic posts are optimized for resonant inductor functions with PCB winding, the second magnetic post for transformer functions, and the third magnetic post for output inductor functions. This localized functional differentiation allows efficient use of limited PCB space while maintaining high power density through optimized component placement in each local region.
Data Source
AI summary
A magnetic element, a power module and a power conversion system are provided. The magnetic element includes a main body, a plurality of first magnetic posts, a first common magnetic post and a second magnetic post. A first lateral edge and a second lateral edge of the main body are opposite to each other and extended along a first direction. A third lateral edge and a fourth lateral edge of the main body are opposite to each other and extended along a second direction. The plurality of first magnetic posts are disposed on the main body and arranged along the first direction. The first common magnetic post is disposed on the main body and located at the first magnetic posts. The second magnetic post is disposed on the main body and located at the first common magnetic post.