Segmented Magnetic Core Inductor for High Saturation Current
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Solution Overview
Problem
On-chip magnetic inductive devices used in high-frequency DC-DC converters face challenges with magnetic core saturation at high operating currents, leading to larger device sizes and lower inductance densities, which defeats the purpose of replacing non-magnetic inductive devices.
Innovation Solution
A magnetic inductive device design featuring a segmented magnetic core with magnetic and non-magnetic segments arranged laterally, where the magnetic core is positioned vertically between two winding layers, allowing for a higher saturation current while maintaining a compact size by optimizing the structure of the magnetic core.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If on-chip magnetic inductive devices are used to replace on-board non-magnetic inductive devices, then the size of the IVR is reduced and performance is improved, but the device size increases to handle high operating currents due to magnetic core saturation
Solution Approach 1:
The magnetic core is divided into multiple segments arranged in a ring structure, with each segment containing magnetic material portions positioned at different radial distances from the central axis. This segmentation allows the core to handle high operating currents without saturation while maintaining a compact overall device size suitable for on-chip integration.
Solution Approach 2:
Different portions of the magnetic core have different magnetic material configurations - inner portions closer to the central axis have different magnetic properties compared to outer portions. This local variation in magnetic quality enables the core to operate at high currents without saturation while maintaining high inductance density in the critical regions.
2Reliability
If larger on-chip magnetic inductive devices are used to increase saturation current, then the saturation current is improved, but the inductance density decreases
Solution Approach 1:
The segmented ring structure distributes the magnetic flux path through multiple sections at different radial positions. This allows the magnetic core to achieve high saturation current capacity through the extended flux path while maintaining high inductance density by concentrating magnetic material in the regions that contribute most to inductance.
Solution Approach 2:
The magnetic core transitions from a conventional planar structure to a three-dimensional ring structure with radial depth. This dimensional change allows the magnetic flux to traverse multiple radial levels, increasing the effective magnetic path length and saturation current capacity without increasing the planar footprint, thereby preserving inductance density.
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 saturation current and inductance density of the inductive device, improving its performance and current handling capacity, making it suitable for high-frequency applications without increasing size.
Implementation Method 1
a magnetic core arranged vertically between the first winding layer and the second winding layer, where the magnetic core may include a portion entirely over the first winding layer and entirely under the second winding layer
Implementation Method 2
the portion of the magnetic core may include a magnetic segment and a non-magnetic segment arranged laterally adjacent to each other along the first axis
Data Source
AI summary
An inductive device may be provided, including a first winding layer, a second winding layer arranged over the first winding layer and connected to the first winding layer to form a plurality of turns around a first axis, and a magnetic core arranged vertically between the first winding layer and the second winding layer. The magnetic core may include a portion entirely over the first winding layer and entirely under the second winding layer, where this portion may include a magnetic segment and a non-magnetic segment arranged laterally adjacent to each other along the first axis.