Power Supply Module Inductor Magnetic Core Leakage Voltage
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Solution Overview
Problem
Conventional power supply modules with integrated inductors suffer from leakage voltage due to electromagnetic coupling between inductors, which is caused by air gaps in the magnetic core assembly, leading to inefficiencies and increased size and weight.
Innovation Solution
A power supply module design that integrates a first magnetic core, a second magnetic core, and an intermediate magnetic core without air gaps, where windings are strategically placed to form inductors with magnetic paths that do not pass through air gaps, reducing electromagnetic coupling and leakage voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If air gaps are introduced in the magnetic core assembly to set required inductance, then inductance can be adjusted, but electromagnetic coupling between inductors increases causing leakage voltage
Solution Approach 1:
The magnetic core is segmented into multiple independent magnetic cores (first magnetic core, second magnetic core, third magnetic core) with distinct magnetic paths. Each magnetic core forms a separate inductor with its own winding, preventing electromagnetic coupling between inductors while maintaining adjustable inductance through air gaps in individual cores.
Solution Approach 2:
Air gaps are selectively introduced only in specific magnetic cores (first and second magnetic cores) where inductance adjustment is needed, while the third magnetic core maintains a continuous magnetic path without air gaps. This localized application allows inductance control without creating unwanted electromagnetic coupling.
2Object-generated harmful factors
If multiple separate inductors are used to avoid electromagnetic coupling, then leakage voltage is reduced, but the size and weight of the power supply module increases
Solution Approach 1:
Multiple magnetic cores (first, second, and third magnetic cores) are integrated into a single assembled magnetic core structure that functions as one unified inductor module. The magnetic cores are positioned adjacent to each other with windings wrapped around specific cores, combining multiple inductors into one compact assembly that reduces overall size and weight while maintaining electrical isolation.
Solution Approach 2:
The windings are nested around specific magnetic cores within the assembled magnetic core structure. The first winding is wrapped around the first magnetic core, the second winding around the second magnetic core, and the third winding around the third magnetic core, creating a compact nested arrangement that minimizes the module's footprint while preventing electromagnetic coupling.
3Manufacturing precision
If air gaps are introduced in the magnetic core assembly, then inductance can be adjusted, but the size of the power supply module increases
Solution Approach 1:
Multiple magnetic cores with air gaps are merged into a single compact assembled magnetic core structure. The magnetic cores are positioned adjacent to each other in a space-efficient arrangement, combining the volume-efficient benefits of air-gapped inductors with the compactness of an integrated module design.
Solution Approach 2:
The magnetic cores are arranged in a three-dimensional configuration where the first, second, and third magnetic cores are positioned adjacent to each other in space. The windings are wrapped around specific cores in different spatial dimensions, allowing compact integration while maintaining the necessary air gaps for inductance adjustment.
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 effectively reduces or eliminates leakage voltage between inductors, enhancing the power supply module's efficiency and reducing its size and weight by eliminating air gaps in the magnetic core assembly.
Implementation Method 1
The first winding is disposed on one of a magnetic column of the first magnetic core and a magnetic column of the intermediate magnetic core adjacent to the first magnetic core to form a first inductor of which a first magnetic path being formed between the first magnetic core and the intermediate magnetic core. The second winding is disposed on one of a magnetic column of the second magnetic core and a magnetic column of the intermediate magnetic core adjacent to the second magnetic core to form a second inductor of which a second magnetic path being formed between the second magnetic core and the intermediate magnetic core.
Implementation Method 2
The inductor module includes a first magnetic core, a second magnetic core, an intermediate magnetic core, a first winding and a second winding
Data Source
AI summary
A power supply module having two output voltages includes an inductor module and a main board. The inductor module includes a first magnetic core, a second magnetic core, an intermediate magnetic core disposed therebetween, a first winding and a second winding. The first winding is disposed on one of a magnetic column of the first magnetic core and a magnetic column of the intermediate magnetic core to form a first inductor. The second winding is disposed on one of a magnetic column of the second magnetic core and a magnetic column of the intermediate magnetic core to form a second inductor. There is no air gap at a portion of the intermediate magnetic core where magnetic paths of the first and second inductors pass through together. The inductor module is disposed on the main board. The first winding and the second winding are electrically connected with the main board.