Multi-Phase Coupled Inductor Structure for Balanced Phase Coupling
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Solution Overview
Problem
Existing multi-phase reverse coupled inductors suffer from unbalanced coupling between phases, leading to inefficiencies and poor consistency in magnetic components, which affects the performance and yield of power modules due to complex and asymmetrical magnetic structures that are prone to deformation during manufacturing.
Innovation Solution
A multi-phase coupled inductor design featuring at least three windings arranged in an array between parallel planes, with a magnetic core comprising a first and second magnetic core and pillars forming magnetic core units that surround the windings, ensuring balanced coupling and consistent inductance, and a manufacturing method that integrates these components for improved precision and yield.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a complex asymmetrical magnetic structure is used to achieve multi-phase reverse coupling, then the coupling between phases can be realized, but the magnetic components are prone to deformation during manufacturing processes such as forming, sintering or hot pressing
Solution Approach 1:
The patent applies asymmetry principle by designing the magnetic core structure with intentional asymmetrical features that compensate for manufacturing variations. The magnetic core includes asymmetrical yokes and limbs arranged in a specific configuration that maintains balanced coupling between phases despite the inherent asymmetry in the structure, thereby resolving the contradiction between achieving proper coupling and preventing deformation during manufacturing
Solution Approach 2:
The magnetic core is segmented into multiple independent parts including first and second magnetic cores with multiple yokes and limbs. This segmentation allows each component to be manufactured separately with controlled dimensions, reducing overall deformation during assembly while maintaining the required coupling characteristics between phases
2Reliability
If a three-dimensional asymmetrical magnetic structure is used, then multi-phase reverse coupling can be achieved, but the forming process becomes complicated and yield decreases
Solution Approach 1:
The complex three-dimensional magnetic structure is divided into multiple separable components including first magnetic core, second magnetic core, and multiple yokes and limbs. Each segment can be manufactured using standard processes, assembled precisely, and the overall structure achieves the required reverse coupling performance while improving manufacturing yield
Solution Approach 2:
The patent transitions from a purely three-dimensional asymmetrical structure to a hybrid structure that utilizes both planar arrangements and vertical stacking. The magnetic cores and yokes are arranged in a configuration that maintains the necessary three-dimensional coupling while incorporating two-dimensional planar elements that are easier to manufacture with high precision
3Reliability
If a complex magnetic structure is used, then coupling between phases can be achieved, but the structure is prone to deformation during sintering or hot pressing
Solution Approach 1:
The magnetic structure is divided into multiple stable segments including first and second magnetic cores with integrated yokes and limbs. Each segment is designed to maintain dimensional stability during sintering or hot pressing, and the segmented architecture distributes thermal and mechanical stresses, preventing overall structure deformation while maintaining phase coupling balance
Solution Approach 2:
Different parts of the magnetic structure have optimized local properties - the yokes and limbs are designed with specific cross-sectional areas and lengths that provide local stability during manufacturing, while the overall arrangement maintains the required coupling characteristics. Each local region is optimized for its specific function and manufacturing requirements
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 design achieves balanced and consistent coupling between phases, enhancing the efficiency and dynamic performance of power modules while simplifying the manufacturing process and reducing costs by using a compact, symmetrical magnetic structure that minimizes deformation and improves precision.
Implementation Method 1
a volume of a magnetic core can be reduced by magnetic integration and magnetic flux reverse offset
Implementation Method 2
reverse coupling between multi-phase circuits is a good solution. A reverse coupled inductor is one of the keys for realizing the multi-phase reverse coupling
Data Source
AI summary
A multi-phase coupled inductor includes at least three windings between a first plane and a second plane and a magnetic core that includes a first magnetic core, a second magnetic core and at least three magnetic core pillars, the first and second magnetic cores are respectively located at two ends of the windings, the magnetic core pillars connect the first and second magnetic cores and form at least three magnetic core units together with the first and second magnetic cores. The magnetic core units and the windings are arranged correspondingly on a one-to-one basis, the magnetic core units surround the corresponding windings and extend from the first plane to the second plane in a same direction, and projections of the at least three magnetic core units on the first plane enclose at least three enclosed areas which correspond to the windings on a one-to-one basis.