Multi-Phase Power Inductor with Segmented Magnetic Core

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Solution Overview

Problem

Existing integrated multi-phase power inductor components face limitations in saturation current performance, form factor, and alternating current resistance due to magnetic core construction, which hinders their effectiveness in higher power and higher current applications.

Innovation Solution

The development of a power inductor component with multiple conductive windings on a common magnetic core structure that includes magnetic gaps, utilizing distributed gap material to reduce fringing flux and alternating current resistance, while maintaining a compact footprint and profile for higher power capability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If multiple windings are integrated in a common core structure, then device complexity is reduced and space is saved, but saturation current performance deteriorates

Engineering Contradiction:

Improveintegrated core structureVSAvoidsaturation current performance

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The magnetic core is divided into multiple separate core pieces, each associated with a specific winding. This segmentation prevents magnetic coupling between windings and allows each core piece to be optimized independently for its winding, thereby maintaining high saturation current performance while preserving the space-saving benefits of integration.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Non-magnetic material is introduced between adjacent windings and core pieces to act as a magnetic shield or barrier. This intermediary prevents fringing flux from one winding from coupling into adjacent windings, eliminating unwanted magnetic coupling effects and improving saturation current performance in the integrated structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of manufacture

If multiple windings are integrated in a common core structure, then manufacturing cost is reduced, but alternating current resistance increases

Engineering Contradiction:

Improvemanufacturing costVSAvoidalternating current resistance

Core Design Contradiction:

Ease of manufactureVSObject-affected harmful factors

Solution Approach 1:

By separating the magnetic core into discrete pieces for each winding, the design eliminates fringing flux paths that would otherwise create high alternating current resistance. Each core piece is optimized for its specific winding, reducing eddy current losses and improving Q-factor while maintaining cost-effective integrated manufacturing.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Non-magnetic material positioned between windings serves as a barrier to fringing flux, preventing it from inducing unwanted currents in adjacent windings. This reduces alternating current resistance and improves overall efficiency of the integrated multi-winding structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Area of stationary object

If compact footprint is maintained, then device size is reduced, but saturation current performance deteriorates

Engineering Contradiction:

ImprovefootprintVSAvoidsaturation current performance

Core Design Contradiction:

Area of stationary objectVSReliability

Solution Approach 1:

The segmented core structure allows each core piece to be tightly coupled with its associated winding, maximizing magnetic coupling efficiency within a compact footprint. This independent optimization enables high saturation current performance without requiring excessive space, as each winding-core pair operates independently without interference from adjacent windings.

Inventive Principle:

Principle #1Segmentation

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 enhances saturation current performance, reduces alternating current resistance, and enables the component to handle higher power and current applications effectively, with a simplified assembly process and lower manufacturing costs.

Implementation Method 1

Power inductors are designed to induce magnetic fields via current flowing through one or more conductive windings, and store energy via the generation of magnetic fields in magnetic cores associated with the windings

Methodology Applied

Scientific EffectElectromagnetic induction: Electromagnetic Induction

Implementation Method 2

utilizing distributed gap material to reduce fringing flux and alternating current resistance

Methodology Applied

Scientific EffectMagnetic fringing:

Implementation Method 3

Methodology Applied

Scientific EffectMagnetic energy storage:

Data Source

PatentUS11361897B2Integrated multi-phase non-coupled power inductor and fabrication methods

Publication Date: 2022.06.14 EATON INTELLIGENT POWER LTD

AI summary

A multi-phase integrated power inductor component assembly includes a plurality of conductive windings on an integrated magnetic core structure accepting each of the plurality of conductive windings in a spaced apart, non-coupled arrangement with respect to one another. The integrated magnetic core structure includes a series of magnetic gaps each being respectively centered on one of the plurality of conductive windings. The windings include surface mount terminations for connection to a circuit board.