Nested Dual Winding Inductor Structure for High Magnetic Coupling
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Solution Overview
Problem
Conventional coupled inductors used in trans-inductor voltage regulators (TLVRs) suffer from low coupling coefficients, insufficient magnetic material filling, poor winding contact, low power density, and inadequate heat dissipation, which are inadequate for microprocessors requiring high current and fast dynamic responses.
Innovation Solution
A coupled dual winding structure with an inner and outer winding, where the outer winding has a through groove and the inner winding is disposed within this groove, enhancing magnetic coupling and insulation, achieving a coupling coefficient exceeding 0.98.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional coupling manner is used for TLVR inductor, then manufacturing is simpler, but coupling degree is low and dynamic response is slow
Solution Approach 1:
The patent implements nested winding structure where the first winding is placed inside the second winding, and the third winding is placed inside the fourth winding. This nested configuration maximizes magnetic coupling between windings while maintaining a compact structure, achieving coupling degree greater than 0.98 without significantly increasing device complexity.
Solution Approach 2:
The patent transitions from planar winding arrangement to three-dimensional nested winding structure. By utilizing spatial dimensionality, the windings are arranged concentrically with different diameters, enabling strong magnetic coupling while maintaining manufacturability through standardized winding processes.
2Power
If conventional inductor structure is used, then manufacturing is easier, but magnetic material cannot be fully filled and power density is low
Solution Approach 1:
The magnetic core is segmented into multiple sections with varying cross-sectional areas, allowing magnetic material to be fully utilized without waste. The segmented structure enables complete filling of magnetic material while maintaining ease of manufacture through modular assembly processes.
Solution Approach 2:
The nested winding structure creates efficient use of internal space, allowing magnetic material to be completely filled within the winding bobbins. The concentric arrangement maximizes the utilization of magnetic material volume, thereby increasing power density without complicating the manufacturing process.
3Temperature
If conventional winding arrangement is used, then manufacturing is simpler, but heat dissipation is insufficient
Solution Approach 1:
The winding structure is segmented into multiple independent windings with insulation layers between them. This segmentation creates thermal pathways and reduces heat concentration, improving heat dissipation while maintaining manufacturing simplicity through standardized winding and insulation processes.
Solution Approach 2:
The patent utilizes three-dimensional spatial arrangement of windings with different diameters and positions. This dimensional arrangement creates natural thermal convection pathways and improves heat dissipation surface area without requiring additional cooling structures, thereby enhancing heat dissipation without significantly increasing device complexity.
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 achieves almost full coupling, enabling quick response and reduced losses, improving the efficiency and performance of trans-inductor voltage regulators.
Implementation Method 1
the inner winding and an outer winding which are coupled to each other... achieving a coupling coefficient exceeding 0.98
Data Source
AI summary
Provided are a coupled dual winding structure and an inductor. The coupled dual winding structure includes an inner winding and an outer winding which are coupled to each other and are insulated from each other. The outer winding includes a through groove, the through groove penetrates through the outer winding in an extension direction of the through groove, and the inner winding is disposed within the through groove and penetrates through the through groove in the extension direction of the through groove, so that the magnetic force lines generated after the current flows through the inner winding pass through the outer winding to the maximum extent.