Voltage Regulator Module With Concave PCB Inductor
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Solution Overview
Problem
Conventional voltage regulator modules face challenges in miniaturization and dynamic switching performance due to the large size and structural limitations, particularly with the magnetic element and switch element being on the same side of the printed circuit board, and issues during reflow soldering processes.
Innovation Solution
A voltage regulator module design featuring a circuit board assembly with a printed circuit board and a magnetic core assembly, where the magnetic core is accommodated within a concave structure on the printed circuit board, allowing for reduced size and enhanced heat dissipation, and a simplified fabrication process through the use of protrusion posts and a molding compound layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the magnetic element and switch element are disposed on the same side of the printed circuit board, then the structure is simplified, but the volume of the voltage regulator module cannot be effectively reduced
Solution Approach 1:
The patent transitions from a planar layout to a three-dimensional stacked architecture. The magnetic element is positioned on the first surface of the printed circuit board while the switch element is positioned on the second surface, utilizing the vertical dimension (thickness direction) to separate components. This dimensional change enables both simplification of internal structure and reduction of overall module volume by eliminating the need for large vacant spaces required in planar layouts.
2Volume of moving object
If the magnetic element size is reduced to minimize module volume, then the volume is reduced, but it becomes difficult to optimize the structure and size of the magnetic element
Solution Approach 1:
The patent divides the voltage regulator module into distinct functional assemblies: a magnetic element assembly containing the magnetic element, and a circuit board assembly containing the switch element. This segmentation allows each component to be independently optimized and manufactured. The magnetic element can be precisely sized and structured according to electrical requirements without being constrained by the need to accommodate switch elements in vacant spaces, thereby facilitating easier optimization while achieving compact overall volume.
3Ease of manufacture
If the voltage regulator module is placed on the system board for reflow soldering, then the manufacturing process is simplified, but the inner components may be detached or shifted due to reheating
Solution Approach 1:
The patent merges the magnetic element and switch element into a single integrated voltage regulator module that is mounted as one unit on the system board. This unified structure ensures that all internal components experience uniform thermal expansion and contraction during reflow soldering, preventing relative displacement or detachment between components. The integrated design maintains component stability while enabling simplified manufacturing through standard reflow soldering processes.
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 effectively reduces the size and height of the voltage regulator module, enhances dynamic switching performance, and stabilizes components during reflow soldering, resulting in improved thermal management and manufacturing efficiency.
Implementation Method 1
at least one inductor is defined by the at least one protrusion post and the magnetic core assembly collaboratively
Implementation Method 2
The voltage regulator module 12 is used for converting an input voltage into a regulated voltage
Data Source
AI summary
A voltage regulator module includes a circuit board assembly and a magnetic core assembly. The circuit board assembly includes a printed circuit board and at least one switch element. A first concave structure is concavely formed on a second surface of the printed circuit board. At least one protrusion post is disposed within the first concave structure. A pin as a positive output terminal, a pin as a positive input terminal and a pin as a negative output terminal are disposed on the second surface of the printed circuit board. The switch element is disposed on a first surface of the printed circuit board. The magnetic core assembly is accommodated within the first concave structure, and includes at least one opening. The protrusion post is penetrated through the corresponding opening. Consequently, at least one inductor is defined by the at least one protrusion post and the magnetic core assembly collaboratively.