Vertical PCB Inductors for High Current Power Conversion
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Solution Overview
Problem
Conventional power converters with planar magnetic components are expensive and inefficient due to the high number of layers and conductive material required for high current applications, making it difficult to manufacture and integrate inductors and circuitry on multilayer PCBs, especially for small footprint and low voltage, high current requirements.
Innovation Solution
A vertical printed circuit board (PCB) inductor module with a magnetic core and conductive traces forming windings, where the contacts are arranged along one edge to facilitate stable orthogonal mounting, reducing the number of conductive layers needed and allowing for a smaller footprint, and using thermally conductive materials for encapsulation while keeping contacts exposed for connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional planar magnetic components are used in power converters, then the inductors can be manufactured on PCB, but the number of conductive layers and PCB area increase significantly for high current applications
Solution Approach 1:
The patent transitions from planar magnetic components to vertical magnetic components, changing the dimensional orientation of the inductor structure. The vertical inductor module stands perpendicular to the PCB surface, with the magnetic core extending vertically and windings wrapped around the vertical core, thereby reducing the number of conductive layers needed on the PCB while maintaining high current capability
Solution Approach 2:
The patent separates the inductor function from the PCB circuitry by using a discrete vertical inductor module that mounts to the PCB surface. This segmentation allows the inductor to be constructed with vertical windings around a vertical core, independent of the PCB's conductive layer structure, reducing the complexity of integrating high-current inductors into multilayer PCBs
2Ease of manufacture
If conventional planar magnetic components are used, then inductors can be integrated on PCB, but the PCB area and footprint increase
Solution Approach 1:
The vertical inductor module utilizes the vertical dimension (Z-axis) rather than expanding horizontally across the PCB surface. By standing perpendicular to the PCB with a compact footprint, the vertical configuration reduces the area occupied on the PCB while maintaining the necessary inductance and current handling capabilities through the vertical winding structure
3Area of stationary object
If vertical PCB surface mount inductors are used, then the footprint is reduced, but stable mechanical connection requires sufficiently wide edges and contacts
Solution Approach 1:
The vertical inductor module employs an asymmetric mounting configuration where the bottom surface provides the primary mechanical support area, and the side surfaces (edges) provide additional stabilization. This asymmetric distribution of contact surfaces optimizes the mechanical connection by concentrating the load-bearing function on the broad bottom surface while using the vertical edges for positional stability and solder attachment
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 solution reduces the cost and complexity of manufacturing power converters by minimizing the number of conductive layers and PCB area, enabling efficient power conversion with a smaller footprint, suitable for high current and low voltage applications, while maintaining mechanical and electrical stability.
Implementation Method 1
using thermally conductive materials for encapsulation
Implementation Method 2
conductive traces that form at least one winding coupled to the magnetic core
Implementation Method 3
an inductor is a passive electronic component that stores energy (measured in henrys (H)) in the form of a magnetic field
Data Source
AI summary
An vertical PCB inductive device is adapted to be surface mount soldered to a substrate. The inductive device may comprise a transformer having a plurality of windings or one or more discrete inductive devices. The inductive device, being amenable to volume production, may also provide cost savings by reducing the number of layers and the PCB area otherwise required by planar magnetics in a power converter. A power converter may be fashioned to be vertically oriented and surface mount soldered to a substrate such as a customer PCB.