Power Supply Module Stacked Windings
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Solution Overview
Problem
Current power supply modules face challenges in achieving high power density and efficiency due to uneven current distribution and large footprint, especially when compressed in height, as well as complex assembly and inflexible device arrangement in transformer-based DC-DC conversion systems.
Innovation Solution
A power supply module design featuring a magnetic core with parallel magnetic plates and windings arranged in a stacked structure, where the magnetic loop and windings are compressed to maintain even magnetic flux and current distribution, allowing for a more compact and flexible arrangement of switching devices and windings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If a planar transformer structure with vertical winding is used, then the module height can be reduced, but the winding becomes thin causing uneven current distribution and increased loss
Solution Approach 1:
The patent transitions from a vertical winding arrangement (single-plane) to a horizontal winding arrangement on stacked circuit boards (multi-dimensional). The magnetic core is rotated 90 degrees and windings are distributed across multiple horizontal layers, transforming the three-dimensional space utilization and maintaining adequate winding thickness while reducing module height.
Solution Approach 2:
The transformer is segmented into multiple independent circuit boards stacked vertically, each carrying partial windings. This segmentation allows each winding layer to maintain sufficient thickness for current distribution while the overall module height is reduced through compact vertical stacking.
2Adaptability or versatility
If the magnetic core is inserted into the winding through assembly, then the structure is flexible, but the assembly tolerance is large causing large footprint and increased loss
Solution Approach 1:
The magnetic core and windings are merged into an integrated structure where the magnetic core is positioned between circuit boards with windings formed around it. This integration reduces assembly tolerance requirements while maintaining structural flexibility through the modular circuit board design.
3Length of moving object
If the magnetic core is made thinner to reduce module height, then the footprint is reduced, but the magnetic loop becomes more uneven affecting efficiency
Solution Approach 1:
The magnetic core is reoriented from a vertical configuration to a horizontal configuration, with the magnetic loop extending in the horizontal plane rather than vertically. This dimensional change allows the core to be thin in the vertical direction (reducing module height) while maintaining adequate magnetic path area through horizontal extension.
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 efficiency and power density by ensuring even current distribution and reducing parasitic inductance, while allowing for a more compact and flexible arrangement of components, addressing the limitations of traditional transformer structures.
Implementation Method 1
a first magnetic plate and a second magnetic plate below the first magnetic plate, and parallel to the first magnetic plate, the first magnetic plate and the second magnetic plate forming a magnetic loop
Implementation Method 2
at least a part of the first upper wiring layer and at least a part of the first middle wiring layer are connected to form a first winding surrounding the first magnetic plate, at least a part of the first lower wiring layer and at least a part of the first middle wiring layer are connected to form a second winding surrounding the second magnetic plate
Data Source
AI summary
The disclosure provides a power supply module, including: a pin; a magnetic core including: a first and second magnetic plate arranged in parallel; a first upper wiring layer; a first middle wiring layer; a first lower wiring layer, wherein at least a part of the first upper wiring layer and the first middle wiring layer are connected to form a first winding surrounding the first magnetic plate, at least a part of the first lower wiring layer and the first middle wiring layer are connected to form a second winding surrounding the second magnetic plate. The magnetic core, the first and second winding form a magnetic element electrically connected to a switch. A magnetic loop surrounds a first axis, the first winding surrounds a second axis, the second winding surrounds a third axis, the first, second and third axis are parallel to a plane where the pin is located.