Segmented Magnetic Core Assembly for Low-Loss Power Density
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Solution Overview
Problem
Conventional magnetic elements used in data centers suffer from low power density and conversion efficiency due to non-uniform current distribution and dimensional inaccuracies, leading to increased size and reduced wiring flexibility.
Innovation Solution
A magnetic element design featuring independently arranged magnetic parts within separate accommodation spaces on a substrate, allowing precise polishing and positioning, thereby enhancing dimension precision and reducing magnetic loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional magnetic element with an integral magnetic core is used, then the structure is simple, but the dimensional precision is poor and magnetic loss is high
Solution Approach 1:
The magnetic core is divided into multiple independent magnetic parts (first magnetic part, second magnetic part, third magnetic part, fourth magnetic part) that are arranged separately and connected through magnetic flux. Each magnetic part can be independently manufactured and polished to high precision, then assembled into the complete magnetic core structure, thereby achieving both high dimensional precision and reduced magnetic loss while maintaining reasonable structural complexity.
2Manufacturing precision
If the magnetic core is finely polished to increase dimension precision, then the dimensional accuracy improves, but the production time increases and outer surfaces may be damaged
Solution Approach 1:
By segmenting the magnetic core into multiple independent magnetic parts, each part can be polished separately and simultaneously in parallel processes. This reduces the total polishing time compared to polishing a large integral magnetic core, while still achieving high dimensional precision for each component.
Solution Approach 2:
The magnetic parts are pre-formed with precise dimensions through molding before assembly. This preliminary precision forming reduces the amount of material that needs to be removed during polishing, thereby reducing polishing time and the risk of surface damage while maintaining high dimensional accuracy.
3Quantity of substance
If the width of the wiring layer is much greater than its thickness, then the wiring capacity is sufficient, but the current distribution becomes non-uniform and impedance varies
Solution Approach 1:
The patent transitions from a planar wiring layer structure to a three-dimensional winding structure where conductors are wound around magnetic parts in multiple layers and directions. This dimensional change allows for more uniform current distribution and impedance control while maintaining sufficient wiring capacity, as the windings can be designed with consistent cross-sectional dimensions throughout their length.
4Power
If the switching frequency of the power supply is increased to achieve high power density, then the power density improves, but the magnetic loss increases
Solution Approach 1:
The segmented magnetic core structure with multiple independently arranged magnetic parts reduces magnetic flux leakage and improves magnetic path efficiency. This allows the magnetic element to operate more efficiently at higher switching frequencies, achieving high power density while minimizing magnetic losses through improved magnetic coupling and reduced eddy current effects.
Solution Approach 2:
The patent optimizes geometric parameters of the magnetic parts including their dimensions, spacing, and arrangement to minimize magnetic loss at high switching frequencies. By carefully controlling parameters such as the distance between magnetic parts, their cross-sectional areas, and the winding configurations, the magnetic element achieves low loss operation at elevated switching frequencies required for high power density applications.
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 design achieves higher power density and reduced magnetic loss by ensuring precise placement and reduced interaction forces, enabling smaller size and improved wiring flexibility.
Implementation Method 1
The magnetic element includes a magnetic core and a plurality of windings. The windings are formed in corresponding wiring layers of the substrate. The magnetic core passes through the substrate.
Data Source
AI summary
A magnetic element includes a magnetic core assembly and a winding assembly. The magnetic core assembly includes a first magnetic part and a second magnetic part arranged independently. The winding assembly includes a first winding. The first winding is wound around the first magnetic part. Moreover, at least a portion of a substrate is formed as the first winding. The substrate includes a first accommodation space, a second accommodation space and a first metal structure. Moreover, at least a portion of the first metal structure is formed as at least a portion of the first winding. At least a portion of the first magnetic part and at least a portion of the second magnetic part are disposed within the first accommodation space and the second accommodation space, respectively. The substrate has an integral structure.