Multi-row coupled inductor width reduction
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Solution Overview
Problem
Conventional coupled inductors with windings in a single row have a large width, which is problematic for applications requiring small component width, and they often result in excessive leakage inductance that can negatively impact the performance of multi-phase switching power converters.
Innovation Solution
The development of multi-row coupled inductors where windings are distributed across multiple rows, allowing for a significantly smaller width and adjustable leakage inductance, achieved through a magnetic core design with opposing plates and coupling teeth, enabling inverse magnetic coupling and optimized magnetic flux paths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If windings are arranged in a single row in conventional coupled inductors, then the structure is simple, but the width becomes large which is problematic for compact applications
Solution Approach 1:
The patent transitions from a single-row winding arrangement to a multi-row winding arrangement, utilizing the third dimension (height/vertical direction) to distribute windings. This dimensional change allows the inductor to achieve compact width while maintaining structural organization through multiple rows of coupling teeth and windings arranged vertically between opposing magnetic plates.
Solution Approach 2:
The patent segments the winding structure into multiple rows, with each row containing coupling teeth and associated windings. This segmentation allows independent optimization of each row's magnetic coupling characteristics while achieving overall compact dimensions through the distributed multi-row configuration.
2Reliability
If conventional coupled inductors are used, then magnetic coupling is achieved, but leakage inductance becomes excessive which negatively impacts multi-phase switching power converter performance
Solution Approach 1:
The patent applies local quality by providing different magnetic path characteristics for different regions of the inductor. The coupling teeth in each row create localized magnetic coupling zones with optimized flux paths, while the overall multi-row structure distributes the magnetic energy storage function. This allows optimization of magnetic coupling in critical areas while managing leakage inductance through the distributed configuration.
Solution Approach 2:
The patent changes the structural parameters of the magnetic core by introducing multiple rows of coupling teeth with specific geometric configurations. This alters the magnetic flux distribution and coupling characteristics, enabling optimization of both magnetic coupling strength and leakage inductance values to achieve desired performance in multi-phase power converters.
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 configuration reduces the overall width of the coupled inductors while maintaining or improving the performance of multi-phase switching power converters by minimizing leakage inductance and enhancing magnetic coupling, leading to better transient response and efficiency.
Implementation Method 1
Magnetizing inductance is associated with magnetic coupling between windings; thus, the larger the magnetizing inductance, the stronger the magnetic coupling between windings
Implementation Method 2
Leakage inductance, on the other hand, is associated with energy storage. Thus, the larger the leakage inductance, the more energy stored in the inductor. Leakage inductance results from leakage magnetic flux, which is magnetic flux generated by current flowing through one winding of the inductor that is not coupled to the other windings of the inductor
Data Source
AI summary
A multi-row coupled inductor has length, width, and height and includes a magnetic core including (1) opposing first and second plates separated from each other in the height direction, and (2) one or more pairs of coupling teeth. Each of the one or more pairs is separated from each other in the widthwise direction, and each of the one or more pairs includes a first coupling tooth and a second coupling tooth separated from and opposing each other in the lengthwise direction. The multi-row coupled inductor further includes: (1) a respective first winding wound around the first coupling tooth, and (2) a respective second winding wound around the second coupling tooth. The first winding mirrors the second winding in each of the one or more pairs, when seen looking toward the magnetic core cross-sectionally in the height direction.