Powder Core Coupled Inductor with Embedded Windings
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Solution Overview
Problem
Conventional coupled inductors in multi-phase DC-DC converters face challenges in achieving optimal leakage inductance and magnetic coupling, leading to inefficiencies in ripple current management and transient response.
Innovation Solution
The development of coupled inductors with multiple windings embedded in a monolithic magnetic core formed from powdered magnetic material, where windings are physically separated to create leakage inductance and magnetically coupled for efficient magnetic flux transfer, allowing for adjustable leakage and magnetizing inductance through core composition and winding alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If windings are physically separated within the magnetic core, then leakage inductance is increased and ripple current management is improved, but magnetic coupling between windings is reduced
Solution Approach 1:
The patent applies local quality by creating different spatial relationships between windings within the same magnetic core. Specifically, certain windings are positioned in close proximity to each other to achieve strong magnetic coupling for efficient energy transfer, while other windings are deliberately separated to generate appropriate leakage inductance for ripple current management. This localized variation in spatial arrangement allows simultaneous optimization of both magnetic coupling and leakage inductance within the same inductor component.
2Volume of moving object
If multiple windings are embedded in a monolithic magnetic core, then inductance values are optimized and device size is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-positioning multiple windings within the magnetic core structure before final assembly. The windings are arranged in specific configurations during the manufacturing process to achieve desired inductance values and coupling characteristics, rather than requiring post-manufacturing adjustments. This pre-arrangement of windings simplifies the overall manufacturing process despite the complexity of embedding multiple windings in a monolithic core.
Solution Approach 2:
The patent employs composite materials by integrating multiple windings made of different conductive materials (such as copper and aluminum) within a single monolithic magnetic core. This composite structure allows optimization of electrical properties for different windings while maintaining a unified magnetic core, thereby reducing overall device size and improving manufacturing efficiency compared to using separate inductor components.
3Speed
If leakage inductance is increased through winding separation, then transient response is improved, but magnetic flux transfer efficiency is reduced
Solution Approach 1:
The patent applies parameter changes by systematically varying the spatial parameters of winding arrangements within the magnetic core. Specifically, the distance between windings, the orientation of windings relative to each other, and the position of windings within the core cross-section are adjusted to achieve optimal leakage inductance values. These parameter variations enable the inductor to provide appropriate transient response characteristics while maintaining sufficient magnetic flux transfer efficiency for the intended application.
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 enhances the efficiency of ripple current management and transient response in DC-DC converters by optimizing leakage inductance and magnetic coupling, reducing core losses and enabling smaller, cost-effective solutions.
Implementation Method 1
The magnetic core provides a path for magnetic flux to magnetically couple the windings
Implementation Method 2
The second winding is at least partially physically separated from the first winding within the magnetic core, creating leakage inductance
Data Source
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AI summary
A multi-phase coupled inductor includes a powder core material magnetic core and first, second, third, and fourth terminals. The coupled inductor further includes a first winding at least partially embedded in the core and a second winding at least partially embedded in the core. The first winding is electrically coupled between the first and second terminals, and the second winding electrically is coupled between the third and fourth terminals. The second winding is at least partially physically separated from the first winding within the magnetic core. The multi-phase coupled inductor is, for example, used in a power supply.