Planar Magnetic Winding Segmentation for Even Current Distribution
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Solution Overview
Problem
Existing power supply technologies for data processing servers face challenges in achieving high efficiency, high power density, and small volume due to uneven current distribution in metal windings, particularly in low-voltage high-current applications.
Innovation Solution
A magnetic element with a multi-turn metal winding structure is developed, where the metal wiring layer is flat wound on a magnetic core and mechanically divided to form a multi-turn winding, ensuring even current distribution by maintaining consistent equivalent impedances across the winding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a wiring-layer metal winding with vertical-winding structure is used, then the winding can be formed on PCB wiring layer, but the current distribution becomes uneven and via losses increase
Solution Approach 1:
The patent divides the metal winding into multiple independent segments arranged in parallel. Each segment is formed on a separate PCB wiring layer and connected through magnetic cores, allowing current to distribute evenly across multiple paths rather than forcing all current through a single vertical winding structure.
Solution Approach 2:
The patent transitions from a vertical winding structure (perpendicular to PCB) to a horizontal planar arrangement where multiple winding segments are distributed across different PCB layers. This dimensional change eliminates the need for long vertical vias and enables even current distribution through parallel horizontal paths.
2Power
If switching frequency is increased to achieve high power density, then power supply efficiency improves, but losses in traditional winding structures increase
Solution Approach 1:
By segmenting the winding into multiple parallel paths, the patent reduces the current burden on each individual path and minimizes via losses. The segmented structure allows for optimized current distribution that reduces resistive losses, enabling high power density operations with lower energy losses.
Solution Approach 2:
The patent replaces the traditional mechanical vertical winding structure with a planar PCB-based implementation. This substitution eliminates the need for physical wire winding and associated via connections, reducing mechanical losses and enabling higher switching frequencies with improved efficiency.
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 even current distribution in the metal winding, enhancing the power supply's efficiency and power density while reducing volume, thus addressing the challenges faced by existing technologies.
Implementation Method 1
a magnetic element, a manufacturing method of a magnetic element, and a power module... a multi-turn metal winding structure... flat wound on a magnetic core
Data Source
AI summary
The present disclosure provides a manufacturing method of a magnetic element, comprising: forming an insulation layer on an outer side of at least one section of a magnetic column of a magnetic core; forming a metal wiring layer on an outer side of the insulation layer through a metallization process; and dividing at least part of the metal wiring layer into a multi-turn metal winding through a mechanically dividing process.