Polyphase Switching Regulator With Integrated Magnetics for Ripple Control
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Solution Overview
Problem
Conventional polyphase switching regulators face challenges in reducing the size, mass, and winding loss of magnetic elements while maintaining efficient heat transfer and minimizing ripple currents, which affects the overall efficiency and complexity of the system.
Innovation Solution
The integration of multiple inductors into a single magnetic element with a core composed of solid materials, such as magnetic laminations or ferrite, and the use of thermally conductive materials for efficient heat removal, along with a control circuit to manage duty cycles and flux density, reduces the size and mass of magnetic components and minimizes ripple currents.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of stationary object
If multiple inductors are integrated into a single magnetic element, then the size and mass of magnetic components are reduced, but the winding loss and heat transfer efficiency become critical challenges
Solution Approach 1:
Multiple inductors are integrated into a single magnetic element with shared magnetic core, reducing the total mass and volume of magnetic components while maintaining the required inductance values for each phase
Solution Approach 2:
The magnetic element is designed with optimized local winding structures and thermal pathways to minimize winding loss in high-current regions while maintaining overall compactness
2Weight of stationary object
If multiple inductors are integrated into a single magnetic element, then the size and mass of magnetic components are reduced, but the heat transfer efficiency becomes a critical challenge
Solution Approach 1:
Multiple inductors share a common magnetic core and thermal management structure, reducing overall size while consolidating heat generation points for more efficient thermal management
Solution Approach 2:
Thermally conductive materials are introduced as intermediaries between the windings and heat sinks to enhance heat transfer efficiency from the integrated magnetic element
3Object-generated harmful factors
If the mutual inductance between windings is increased to reduce ripple currents, then the ripple current cancellation is improved, but the complexity of magnetic element design increases
Solution Approach 1:
Multiple windings are coupled on a shared magnetic core to achieve mutual inductance for ripple current cancellation, reducing the need for separate filtering components
Solution Approach 2:
The mutual inductance parameter is optimized to achieve effective ripple current cancellation while maintaining manageable design complexity through standardized magnetic core geometries
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 approach significantly reduces the size and mass of magnetic components, enhances heat transfer, and minimizes ripple currents, leading to improved efficiency and reduced complexity in polyphase switching regulators.
Implementation Method 1
During the on-time, part of the energy applied to high voltage 102 is transferred to low voltage port 116 and the remainder is stored in inductor 195. During the off-time, the energy previously stored in inductor is transferred to low voltage port 116.
Implementation Method 2
the design of the magnetic element may be such that efficient heat transfer is achieved both for the windings and the ferro-core
Data Source
AI summary
A switching regulator is disclosed comprising a high-voltage port, a low-voltage port, n number of switching poles, a magnetic element, and a controller. In turn, each switching pole connects across the high-voltage port and may consist of either one switch and one diode or two switches and two diodes. In turn, the magnetic element comprises a ferro-core having n number of magnetic branches, each of which includes a winding. Each winding start connects to the phase node of a respective switching pole, while each winding finish connects, in common, to one side of the low-voltage port. An n+1th magnetic branch establishes a defined common-mode inductance which, in combination with transformer action, limits current ripple. The transformer action serves to exchange ripple power between phases such that the need for inductance is greatly reduced.