Multi-Tier PCB Wave Filter for Compact High-Current DCDC Output
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Solution Overview
Problem
Existing on-board power DCDC conversion products face challenges with high-current wave-filters that occupy large installation space and result in current loss and coil heat, making them inefficient and difficult to miniaturize.
Innovation Solution
A multi-tier wave-filter design using N-tiered PCB boards with N−1-level output inductors and capacitors connected between adjacent PCB boards, along with a filter output terminal, which reduces installation space and enhances heat dissipation and filtering capabilities by using flat copper bars for inductors and separate magnetic cores for each level.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single large-area monolithic PCB board is used for high-current wave-filters, then the output inductors and capacitors can be distributed on the board, but the installation space occupied is large
Solution Approach 1:
The wave-filter is divided into multiple independent modules, each containing specific inductors and capacitors. These modules are arranged in a segmented layout rather than distributed across a single large PCB, reducing the overall installation space while maintaining functional integrity
Solution Approach 2:
The design transitions from a two-dimensional PCB layout to a three-dimensional modular arrangement, stacking components vertically and utilizing spatial depth to reduce the horizontal footprint of the wave-filter assembly
2Power
If high current flows through the wave-filter, then the output power increases, but current loss and coil heat increase
Solution Approach 1:
The high current path is segmented into multiple parallel current paths through distributed inductor modules. This segmentation reduces the current density in each individual conductor, minimizing resistive losses and heat generation while maintaining high total output power
Solution Approach 2:
Multiple inductor modules act as intermediaries to distribute and share the high current load. Each inductor handles a portion of the total current, reducing the thermal stress and energy loss in any single component while achieving high power output collectively
3Power
If high current flows through the wave-filter, then the output power increases, but coil heat increases
Solution Approach 1:
The coil structure is segmented into multiple separate inductor modules with independent windings. This segmentation distributes the heat generation across multiple components rather than concentrating it in a single large coil, improving thermal management and reducing peak temperatures while maintaining high power output
Solution Approach 2:
Multiple inductor modules serve as thermal intermediaries, each dissipating a portion of the generated heat independently. This distributed thermal management approach prevents heat concentration and facilitates better heat dissipation across the wave-filter assembly
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 multi-tier wave-filter achieves miniaturization, reduces current loss and coil heat, and improves inductance, leading to a compact, high-performance, and cost-effective high-current filter solution.
Implementation Method 1
the high current leads to current loss and coil heat
Implementation Method 2
using flat copper bars for inductors
Implementation Method 3
N−1-level output inductors arranged at intervals from top to bottom
Implementation Method 4
separate magnetic cores for each level
Implementation Method 5
enhances heat dissipation
Data Source
AI summary
The present invention discloses a multi-tier wave-filter and an on-board power source DCDC conversion device. The multi-tier wave-filter includes: N-tiered PCB boards arranged at intervals, wherein N is greater than or equal to 3; N−1-level output inductors arranged at intervals, wherein an output inductor at each level is connected to adjacent upper-tier and lower-tier PCB boards through its input end and output end, respectively; N−1-level output capacitors arranged at intervals, wherein an output capacitor at each level is correspondingly connected to PCB boards between a second tier and a Nth tier, respectively; and a filter output terminal connected to an output end of the N−1-level output inductor. The multi-tier wave-filter provided by the present invention not only achieves miniaturizing the wave-filter and decreasing installation space, but also better enables the high-current path at the output end of the DCDC converter to have heat dissipation, filtering, shielding and other properties.