Low-Profile Inductor Structure Using PCB Copper Strips
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional inductor structures on PCB boards are too tall to meet the requirements of compact voltage regulator modules, as they typically exceed the height of semiconductor components, necessitating a reduction in inductor height without compromising efficiency or size.
Innovation Solution
The inductor structure incorporates hollow PCB boards with spacers or copper strips as windings, allowing the inductor core to be inserted into through holes, reducing the overall height by utilizing the PCB board's layers or thinner copper strips, and enhancing efficiency by minimizing DC resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional discrete inductors are used in voltage regulator modules, then the inductor can provide necessary inductance, but the height of the inductor structure becomes too large, exceeding the height of semiconductor components
Solution Approach 1:
The patent merges the inductor structure with the PCB board by using the PCB's copper foil layers as the inductor windings. The PCB board itself becomes part of the inductor structure, eliminating the need for separate discrete inductor components and significantly reducing overall height while maintaining inductance functionality.
Solution Approach 2:
The patent transitions from three-dimensional discrete inductor components to a two-dimensional planar structure by implementing the inductor windings within the PCB board's copper foil layers. This dimensional change allows the inductor to be integrated flatly into the PCB, dramatically reducing height.
2Length of moving object
If multiphase interleaved buck circuit is used to achieve high frequency operation, then the size and height of magnetic components can be reduced, but the overall inductor height still exceeds requirements for compact voltage regulator modules
Solution Approach 1:
The patent combines the inductor windings with the PCB board's copper foil layers, creating an integrated structure where the PCB serves dual purposes as both the circuit board and the inductor component. This merging eliminates the need for separate magnetic components while maintaining the high-frequency performance required for efficient voltage conversion.
Solution Approach 2:
The PCB board is designed to serve multiple functions simultaneously: it acts as the structural support, the electrical connection medium, and the inductor component itself. The copper foil layers perform both their traditional circuit routing function and the inductor winding function, reducing the need for additional components.
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 achieves a significantly lower overall height for the inductor structure, meeting the compactness requirements while maintaining efficiency by using the PCB board's layers or copper strips as windings, thus addressing the height constraint in voltage regulator modules.
Implementation Method 1
any two adjacent through holes of the plurality of through holes have a spacer therebetween for use as the inductor winding of the inductor structure
Data Source
AI summary
The present disclosure discloses an inductor structure mounted on a PCB board and a voltage regulator module having the same. The inductor structure includes an inductor core and an inductor winding. The PCB board is provided with at least one hollow part, and the inductor structure further comprises a plurality of copper strips used as the inductor windings of the inductor structure. The copper strips are spaced apart in the hollow part so as to form a plurality of through holes, and the leg of the inductor core is correspondingly inserted into the through hole at the corresponding position of the hollow part.