Vertical Magnetic Core Layout for Compact Power Conversion Modules
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Solution Overview
Problem
Conventional power conversion modules face challenges in achieving high power density due to the large volume and loss caused by inductor magnetic cores, particularly with soft-magnetic ferrite materials, which have low saturation magnetization and uneven loss distribution.
Innovation Solution
The design optimizes the power conversion module by arranging a magnetic core set and conductor in a main body layer, with a vertical magnetic core configuration to reduce parasitic impedance and enhance power density, and positions the power device and input capacitor for improved circuit efficiency and reduced volume.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If soft-magnetic ferrite is used as magnetic core material, then the magnetic core can be made compact, but the saturation current is low due to low saturation magnetization
Solution Approach 1:
The patent combines multiple magnetic core layers (first magnetic core layer, second magnetic core layer, third magnetic core layer) to form an integrated magnetic core structure. This merging approach increases the effective magnetic path and saturation current capability while maintaining a compact overall volume, resolving the contradiction between small size and high saturation current.
2Device complexity
If ring design is adopted with sufficient difference between inner diameter and outer diameter, then the magnetic core structure is simple, but the loss distribution in iron powder magnetic core becomes uneven
Solution Approach 1:
The patent segments the magnetic core into multiple thin layers stacked together, where each layer has a controlled width. This segmentation allows for more uniform magnetic flux distribution and reduces eddy current losses compared to a conventional ring design, while maintaining structural simplicity through the repetitive layered pattern.
Solution Approach 2:
The patent transitions from a planar ring design to a three-dimensional layered structure. By stacking multiple magnetic core layers in the vertical dimension, the design achieves more uniform loss distribution while keeping the horizontal footprint compact, effectively resolving the contradiction between structural simplicity and loss uniformity.
3Volume of stationary object
If the magnetic core is embedded between several layers of multilayer printed circuit board, then the power conversion module size is reduced, but the parasitic impedance on output current transmission path increases
Solution Approach 1:
The patent introduces a conductor layer as an intermediary element that provides a low-impedance current path between the power device and the magnetic core. This conductor layer is strategically positioned to minimize loop area and parasitic impedance, allowing the magnetic core to be embedded in the PCB while maintaining low parasitic impedance in the current transmission path.
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 configuration reduces parasitic parameters, increases power density, and simplifies assembly while optimizing heat dissipation and signal transmission, achieving a more compact and efficient power conversion module.
Implementation Method 1
arranging a magnetic core set and conductor in a main body layer to construct the magnetic component
Implementation Method 2
the magnetic core set is embedded in the main body layer by using a vertical arrangement in the closed path of the magnetic field lines
Data Source
AI summary
The present disclosure provides a power conversion module including a magnetic component and a power device layer. The magnetic component includes a main body layer, a first magnetic core, a second magnetic core and a conductor. The main body layer includes a first surface and a second surface opposite to each other. The first magnetic core is embedded in the main body layer and adjacent to the first surface. The second magnetic core is embedded in the main body layer and adjacent to the second surface. The first magnetic core and the second magnetic core are connected to form plural magnetic columns. The conductor is embedded between the first surface and the second surface. The conductor is partially disposed between the plural magnetic columns. The power device layer is disposed on the first surface. The power device layer includes a power device electrically connected to conductor.