Tapered Integrated LC Components for Power Converter Loss Reduction
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Solution Overview
Problem
Integrated LC components for power converters suffer from high losses and larger sizes due to non-uniform current density and high eddy current losses, particularly with solid copper conductors at high operating frequencies.
Innovation Solution
The use of tapered conductors with varying widths, separated by gaps, to achieve a more uniform current distribution and reduce losses, along with encapsulation in flexible organic polymers and folding techniques to enhance capacitance and reduce eddy current losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If solid copper conductors are used in integrated LC components, then electrical conductivity is improved, but eddy current losses increase at high operating frequencies
Solution Approach 1:
The solid copper conductor is segmented into multiple parallel conductive strips separated by insulating material. This segmentation breaks up the continuous conductive path that causes eddy currents, thereby reducing eddy current losses while maintaining overall electrical conductivity. Each strip carries a portion of the current, and the insulating barriers between them prevent circulating eddy currents.
Solution Approach 2:
The conductor structure uses a composite construction combining conductive copper strips with insulating material (such as polyimide or other dielectric layers). This composite structure allows the conductive paths to carry current efficiently while the insulating portions block eddy current formation, achieving both good conductivity and low losses.
2Ease of manufacture
If constant width conductors are used, then manufacturing simplicity is improved, but current density uniformity deteriorates
Solution Approach 1:
The conductor width varies along its length, with wider sections at the ends and narrower sections in the middle. This non-uniform width distribution is specifically designed to compensate for the natural tendency of current to concentrate at the ends, creating a more uniform current density throughout the conductor. The local geometry is optimized to achieve uniform electrical performance.
3Use of energy by moving object
If conductor area is increased to reduce resistance, then electrical conductivity is improved, but component size increases
Solution Approach 1:
The conductor parameters (width, thickness, length) are optimized to achieve the minimum necessary cross-sectional area for acceptable resistance while minimizing overall component size. The tapered geometry allows efficient current distribution with reduced material usage compared to constant-width designs.
Solution Approach 2:
The use of high-conductivity copper combined with thin insulating layers allows achieving low resistance without requiring large conductor cross-sections. The composite structure maximizes the conductive path efficiency while minimizing the space occupied by insulating material.
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 results in reduced losses and smaller component sizes, enabling higher power density and efficiency in power converters while maintaining uniform current distribution and minimizing eddy current losses.
Implementation Method 1
a more uniform current distribution and reduce losses
Implementation Method 2
two long conductors separated by a dielectric, which forms a capacitor
Implementation Method 3
This pair of conductors may then be formed into a coil, which enhances its ability to function as an inductor
Implementation Method 4
This can result in high eddy current losses when the operating frequency is high
Data Source
AI summary
An integrated inductor and capacitor component is provided and includes a number of tapered conductors. Neighboring ones of the tapered conductors are separated by a gap extending along a length of the component. A first one of the tapered conductors is characterized by a first width w1 that is larger at a first end of the component and tapers along the length of the component toward a second end of the component, and a second one of the tapered conductors is characterized by a second width w2 that is larger at the second end of the component and tapers toward the first end of the component.