Multi-phase buck converter for slim OLED power modules
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Solution Overview
Problem
Current power converter solutions for OLED lighting are bulky due to the thickness of inductors, leading to energy loss and increased material costs when trying to integrate them into slim OLED panels, with no practical solution available to achieve a slim and cost-effective power module.
Innovation Solution
A multi-phase buck converter technology is employed, utilizing a 4-phase constant current topology with a control circuit forming a stable feedback loop, reducing the number of inductors needed and minimizing magnetic material usage, while maintaining efficient current regulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a single thick inductor is used in a conventional power converter, then the current regulation function is achieved, but the thickness of the power module increases beyond the 1.5mm requirement
Solution Approach 1:
The patent divides a single large inductor into multiple smaller inductors arranged in a multi-phase configuration. Specifically, it uses multiple phases (e.g., 4-phase) with each phase having its own smaller inductor, thereby reducing the thickness of individual inductors to fit within the 1.5mm overall thickness requirement while maintaining the total inductance needed for current regulation.
Solution Approach 2:
The patent transitions from a single thick inductor (one-dimensional solution) to a multi-phase distributed inductor arrangement that utilizes spatial distribution across multiple dimensions. The inductors are arranged in parallel phases, distributing the magnetic path across different spatial locations rather than concentrating it in a single thick component.
2Length of moving object
If multiple smaller thin inductors are used to reduce thickness, then the power module thickness requirement is met, but the occupying area in length and width dimensions increases
Solution Approach 1:
The patent merges multiple inductor phases into a shared magnetic core structure. Instead of using separate standalone inductors that would each require their own space, the inductors share common magnetic paths and core structures, thereby reducing the total occupying area. The magnetic cores are coupled together to form an integrated assembly that fits within the area constraints.
Solution Approach 2:
The patent designs the magnetic core structure to serve multiple functions simultaneously: it provides the magnetic path for multiple inductor phases, acts as the supporting structure for the windings, and serves as the mechanical assembly framework. This multi-functionality eliminates the need for separate components, reducing the overall occupying area.
3Length of moving object
If multiple smaller inductors are used to reduce thickness, then the power module becomes slim, but the component count and assembly complexity increase significantly
Solution Approach 1:
The patent combines multiple inductor assemblies into a single integrated magnetic core structure. Instead of assembling separate inductor components individually, the design merges them into one unified assembly where multiple phases share common magnetic paths, supporting structures, and winding arrangements, thereby reducing assembly complexity despite having multiple phases.
Solution Approach 2:
The patent employs preliminary design and integration of the multi-phase inductor assembly as a pre-assembled unit. The magnetic cores, windings, and supporting structures are configured and assembled together beforehand as an integrated module, which then serves as a complete sub-assembly in the power converter, reducing the complexity of final assembly.
4Length of moving object
If the power converter thickness is reduced to integrate into OLED panels, then panel integration is enabled, but energy loss increases due to transmission constraints
Solution Approach 1:
The patent extracts the power conversion function directly into the OLED panel assembly by integrating the slim multi-phase power converter with the panel structure. This eliminates the need for external power converters connected via long wires, thereby removing the source of transmission energy loss. The power converter is positioned immediately adjacent to or within the panel structure.
Solution Approach 2:
The patent uses the integrated slim power converter as an intermediary between the power source and the OLED elements. This intermediary is positioned close to the load (OLED elements), minimizing the transmission distance and reducing energy loss in the current paths. The multi-phase topology also provides efficient current distribution as an intermediary function.
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 approach results in a slim, cost-effective power module that provides a constant current source for OLED lighting with reduced energy loss and material costs, allowing for integration into thin OLED panels without increasing the panel's width or length.
Implementation Method 1
A multiple-phase buck converter is a currently available technology for voltage conversion... converts a direct current (DC) voltage to the controlled constant current
Data Source
AI summary
A slim and cost effective power module solution derived from the multiple-phase buck converter technology that addresses the problems of inductor thickness and excessive magnetic material use. Such power module solution utilizes a multi-phase constant current topology and a corresponding electronic controller to provide a constant current source for various OLED lighting applications. The multi-phase constant current topology comprises two or more inductor-flyback diode feedback loops. Each inductor-flyback diode feedback loop is triggered ON and OFF out-of-phase by a current controller, which senses and estimates the average current supplied to the load, and causes the adjustments to the average current supplied to the load by controlling the ON duration of the inductor-flyback diode feedback loops.