Multiphase Converter Inverse Coupling Reduces Winding and Core Loss
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Solution Overview
Problem
Existing multiphase buck, boost, and buck-boost converters with inversely coupled inductors face inefficiencies due to high inductor resistance and magnetic core volume, which increase power loss and reduce energy conversion efficiency.
Innovation Solution
The use of a lateral magnetic core with non-looping conductors in the inductors, which reduces conductor resistance and magnetic core volume, achieving inverse coupling with low winding resistance and small core volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If inductors with inverse coupling are used to decrease output current ripple and reduce conduction loss, then transient response is improved, but conductor resistance increases due to extra windings which adversely affects energy conversion efficiency
Solution Approach 1:
The patent transitions from conventional planar inductor layouts to a three-dimensional stacked configuration where inductors are arranged vertically with shared magnetic cores. This spatial reorganization reduces conductor path length and eliminates unnecessary windings while maintaining inverse coupling, thereby reducing resistance without sacrificing transient response performance
Solution Approach 2:
The patent merges multiple inductor functions into shared magnetic core structures where a single core serves multiple inductors simultaneously. This consolidation eliminates redundant magnetic material and conductor windings, reducing both resistance and core volume while preserving the inverse coupling effect needed for fast transient response
2Reliability
If woven topology of inductor core is used for inverse coupling, then inductors can be coupled, but magnetic core volume increases which increases power loss of magnetic core and adversely affects energy conversion efficiency
Solution Approach 1:
The patent replaces the planar woven topology with a vertical stacked arrangement where magnetic cores are positioned in three-dimensional space. This dimensional change allows inductors to achieve inverse coupling through vertical flux paths rather than horizontal weaving, dramatically reducing the horizontal spread and overall volume of magnetic material required
Solution Approach 2:
The patent extracts and eliminates the unnecessary woven structure from the magnetic core design. By removing the complex interlaced topology and replacing it with simpler vertical stacking, the design retains the essential inverse coupling function while minimizing magnetic core volume and associated power losses
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 design enhances energy conversion efficiency and transient response by minimizing inductor power losses and allowing for high current capability and fast transient response in multiphase converters.
Implementation Method 1
coupled inductors with non-looping conductors... The current of the two inductors are in opposite direction. With the unique structure of lateral magnetic core and non-looping conductors, the coupled inductors will be inversely coupled
Implementation Method 2
The magnetic core can be placed between two layers of printed circuit boards, and can have air gap to prevent magnetic saturation
Data Source
AI summary
A multiphase switching DC-DC converter generates an output voltage from an input voltage. The converter includes multiphase coupled inductors having lateral magnetic core and non-looping conductors. The currents in conductors of the inductors flow in opposite directions, and therefore, the coupled inductors are inversely coupled and have a relatively low resistance and relatively small core volume. The reduced resistance of the inductor windings combined with smaller volume of magnetic core in the coupled inductors increases energy conversion efficiency and improves transient response of the converter. The coupled inductors can be employed in buck or boost or buck-boost converters, and they can also be used in buck or boost or buck-boost derived converters with isolation transformers.