Pin-Core Inductor Integration for Compact Power Modules
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Solution Overview
Problem
Magnetic components in power modules occupy a large area on the circuit board, leading to reduced power density and inefficient heat dissipation, with high power loss due to welding-based connections.
Innovation Solution
The inductor is integrated with a magnetic core and a pin that passes through the core's through hole, functioning as a winding, eliminating the need for separate inductors on the circuit board and enhancing heat dissipation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If filter inductor is mounted on circuit board by welding, then inductor can be connected to circuit board, but inductor occupies large area on circuit board
Solution Approach 1:
The patent merges the inductor with the power module housing structure. The housing is designed to include a magnetic component that serves as the inductor, integrating two previously separate functions (housing support and inductance) into a single unified structure. This eliminates the need for a separate inductor component on the circuit board, thereby reducing the occupied area and improving power density.
2Temperature
If filter inductor is mounted on circuit board by welding, then inductor can be connected to circuit board, but heat dissipation is poor
Solution Approach 1:
The patent merges the heat dissipation function into the housing structure. The housing is designed with thermal conductivity considerations and includes features such as heat dissipation fins or conductive pathways that allow efficient heat transfer from the inductor to the housing and ultimately to the surrounding environment. This integrated approach improves heat dissipation compared to welding-only connections.
3Ease of manufacture
If filter inductor is mounted on circuit board by welding, then inductor can be connected to circuit board, but manufacturing complexity increases
Solution Approach 1:
The patent merges the inductor assembly with the housing assembly process. The magnetic component is integrated into the housing structure, allowing it to be manufactured or pre-assembled as part of the housing unit. This reduces the number of separate assembly steps required (no separate inductor mounting, wiring, and soldering operations) and simplifies the overall manufacturing process.
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
Reduces the occupied area, eliminates conduction and wire losses, and improves heat dissipation efficiency while being cost-effective and easier to manufacture.
Implementation Method 1
a pin passes through the through hole of the magnetic core, and acts as a winding to form the inductor together with the magnetic core
Data Source
AI summary
The present application provides an inductor applied to a power module and a power module with the inductor. The inductor comprises a magnetic core, having a through hole, wherein a pin passes through the through hole of the magnetic core, and acts as a winding to form the inductor together with the magnetic core, and the pin is input pins or output pins of the power module. The inductor applied to the power module and the power module provided by present application reduce the area occupied by the inductor on the circuit board of the power module, reduce the conduction power loss of the inductor, eliminate the wire loss between the pin and the inductor, and heat is dissipated through the pin and the magnetic core, which further improves the efficiency of the heat dissipation of the inductor.